JP7494323B2 - Multi-Function Inventory Handling Station Assembly - Google Patents

Description

The present invention relates to the field of storage and retrieval systems for handling storage containers or bins stacked within a grid framework structure, and more particularly to a further multi-function inventory handling station assembly for retrieving or supplying one or more items or goods to or from a storage and retrieval system comprising a grid framework structure.

Storage systems comprising a three-dimensional storage grid structure within which storage containers/boxes are stacked on top of each other are well known. PCT Publication WO 2015/185628 A (Ocado) describes a known storage and procurement system in which stacks of boxes or containers are arranged within a grid framework structure. The boxes or containers are accessed by remotely operable baggage handling devices on tracks mounted above the grid framework structure. A system of this type is shown diagrammatically in Figures 1 to 3 of the accompanying drawings.

As shown in Figures 1 and 2, stackable containers known as boxes or containers 10 are stacked on top of each other to form a stack 12. The stacks 12 are arranged within a grid framework structure 14 in a warehouse or manufacturing environment. The grid framework is comprised of a number of storage or grid columns 15. Each grid within the grid framework structure has at least one grid column for storage of a stack of containers. Figure 1 is a schematic perspective view of the grid framework structure 14, and Figure 2 is a top down view illustrating a stack 12 of boxes 10 arranged within the framework structure 14. Each box 10 typically holds multiple product items (not shown), which may be the same or different product types, depending on the application.

The grid framework structure 14 comprises a plurality of upright members or columns 16 supporting horizontal members 18, 20. A first set 18 of parallel horizontal grid members are arranged at right angles to a second set 20 of parallel horizontal grid members to form a plurality of horizontal grid structures supported by the upright members 16. The members 16, 18, 20 are typically fabricated from metal and typically welded or bolted together or a combination of both. The boxes 10 are stacked between the members 16, 18, 20 of the grid framework structure 14 such that the grid framework structure 14 protects the stack 12 of boxes 10 from horizontal movement and guides the vertical movement of the boxes 10.

The top level of the grid framework structure 14 includes rails 22 arranged in a grid pattern across the top of the stack 12. With further reference to FIG. 3, the rails 22 support a plurality of luggage handling devices 30. A first set 22a of parallel rails 22 guides movement of the robotic luggage handling device 30 in a first direction (e.g., X direction) across the top of the grid framework structure 14, and a second set 22b of parallel rails 22 arranged perpendicular to the first set 22a guides movement of the luggage handling device 30 in a second direction (e.g., Y direction) perpendicular to the first direction. In this manner, the rails 22 allow movement of the robotic luggage handling device 30 laterally in two dimensions in the horizontal XY plane such that the luggage handling device 30 can be moved to a suitable position above either of the stacks 12.

The known luggage handling device 30 illustrated in Figures 4 and 5 is described in PCT Patent Publication WO 2015/019055 (Ocado), incorporated herein by reference, comprising a vehicle body 32, with each luggage handling device 30 covering only one grid space of the grid framework structure 14. Here, the luggage handling device 30 comprises a wheel assembly comprising a first set of wheels 34 consisting of a pair of wheels at the front of the vehicle body 32 and a pair of wheels 34 at the rear of the vehicle 32 for engaging a first set of rails or tracks to guide the movement of the device in a first direction, and a second set of wheels 36 consisting of a pair of wheels 36 on either side of the vehicle 32 for engaging a second set of rails or tracks to guide the movement of the device in a second direction. Each of the set wheels is driven to enable the movement of the vehicle in the X and Y directions along the rails, respectively. One or both sets of wheels are vertically movable to lift each set of wheels away from the respective rails, thereby enabling the vehicle to move in a desired direction.

The load handling device 30 is equipped with a lifting device or crane mechanism for lifting the storage container from above. The crane mechanism comprises a winch, tether, or cable 38 wound on a spool or reel (not shown) and a gripping device 39. The lifting device or crane mechanism comprises a set of lifting tethers 38, also called gripping devices (one tether near each of the four corners of the gripping device) that extend vertically and are connected near or to the four corners of the lifting frame 39 for releasable connection to the storage container 10. The gripping device 39 is configured to releasably grip the top of the storage container 10 lifting it from a stack of containers in a storage system of the type illustrated in Figures 1 and 2.

The wheels 34, 36 are positioned around the periphery of a cavity or recess known as a container receiving recess 40 in the lower portion of the load handling device. The recess is sized to accommodate the container 10 when it is lifted by the crane mechanism, as illustrated in Figures 5(a and b). When in the recess, the container is lifted off the lower rail to allow the vehicle or load handling device to move laterally to a different location. Upon reaching the target location, e.g., another stack, an access point in a storage system, or a conveyor belt, the box or container can be lowered from the container receiving portion and released from the gripping device.

Thus, upon receipt of a customer order, a baggage handling device operable to move on a track is instructed to pick a storage box containing the ordered items from a stack in the grid framework structure and transport the storage box to a pick-up station, after which the items can be retrieved from the storage box. In general, the baggage handling device transports the storage box or storage container to a box lifting device integrated into the grid framework structure. A mechanism of the box lifting device lowers the storage box or storage container to the pick-up station. At the pick-up station, the items are retrieved from the storage box. Removal can be done manually by hand or by a robot as taught in GB2524383 (Ocado Innovation Limited). After retrieval from the storage box, the storage box is transported to a second box lifting device, which is then lifted to the grid level for retrieval by the baggage handling device and transported back to its location in the grid framework structure. A control system and a communication system track the location of the storage boxes and their contents in the grid framework structure. As individual containers are stacked in vertical layers, their locations within the grid framework structure or "hive" may be represented using coordinates in three dimensions to represent the location of the baggage handling device or container and container depth (e.g., container at (X,Y,Z), depth W). Similarly, locations within the grid framework structure may be represented in two dimensions to represent the location of the baggage handling device or container and container depth (e.g., container at (X,Y), depth Z). For example, Z=1 identifies the top layer of the grid, i.e., the layer immediately below the rail system, Z=2 is the second layer below the rail system, and so on down to the bottom layer, which is the lowest layer of the grid.

Similarly, when stocking a storage system with items or replenishing the inventory of a storage system, items delivered from a supplier are transported to a decanting station or a supplying station, where the items are removed from their packaging depending on the type of item, registered into a unique Stock Keeping Unit or SKU, and placed into a storage bin at the decanting station. At the decanting station, the storage bin is transported to a bin lifting device, which then lifts it to grid level for collection by a baggage handling device and transports it to a location within the grid framework structure.

WO2017/211640 (Autostore Technology AS) describes a storage system for storing product items comprising a grid structure, where several storage bins are configured to be stored in vertical compartments within the grid structure, each storage bin being configured to contain at least one product item, the storage system comprising a pick-up and/or supply station, the storage system comprising a conveyor system configured to transport the storage bins from a first position to a second position and further to a third position. The conveyor system comprises a first tiltable conveyor configured to transport the storage bins from the first position through the second position to the third position. The pick-up and/or supply station is provided adjacent to the grid structure. The first and third positions are provided below two different vertical compartments within the grid structure. The tiltable conveyor comprises a hydraulic piston and cylinder mechanism for lowering and raising the conveyor. The tiltable conveyor supports the storage bins in an inclined position in the second position, thus allowing items to be manually removed from the storage bins. Once retrieved, the tiltable conveyor is tilted down and the storage bin is transported to a third location that allows the storage bin to be retrieved by a baggage handling device operable on the grid structure. While using a hydraulic piston and cylinder mechanism to lower and raise rollers suffers from alignment issues to ensure that the storage bin can be transported from the first location through the second location to the third location, the use of such a tilting device adds a level of complexity to the retrieval station.

WO2018/069282 (Autostore Technology AS) describes a pick-up/supply station assembly for a storage system with a grid structure. The pick-up/supply station assembly comprises a first box lifting device, a second box lifting device, and a pick-up/supply station, where the first box lifting device is positionable to receive storage boxes from at least one vehicle at an upper level of the grid structure and deliver the storage boxes to the pick-up/supply station. The pick-up/supply station comprises a box transport assembly positioned to move the storage boxes from the first box lifting device to the second box lifting device, where the second box lifting device is positionable to receive the storage boxes from the box transport assembly and transport the storage boxes to the upper level of the grid structure. The box lifting device is positioned in the storage system to receive storage boxes from a vehicle or a baggage handling device at the upper level of the grid structure and transport the boxes vertically down to a supply/picking station positioned on the first floor of a building in which the storage system is installed. In use, the first storage box is initially placed on the lifting arms at the upper level of the grid and lowered towards the first conveyor unit. The spacing of the lifting arms is wide enough to allow the first conveyor unit to pass between them. During the pass, the first storage box remains on the first conveyor unit, but the lifting arms enter their lowest position. The first storage box is then transported from the first lifting device by the first conveyor unit. After the exit of the storage box from the first box lifting device, the lifting arms may return to the upper level to retrieve the second storage box. The first box lifting device and the second box lifting device are integrated into the grid framework structure, and thus the removal station forms an integral part of the grid framework structure.

A similar box lifting mechanism integrated into a grid framework structure to feed a pick-up station is described in WO2020/074717 (Autostore Technology AS). WO2020/074717 (Autostore Technology AS) describes an access station for picking up storage containers, comprising a pick-up zone, where at least one conveyor is arranged to transport the storage containers from an entry position through said pick-up zone to an exit position, where the access station comprises at least one tilting device arranged to tilt the storage containers at least in the pick-up zone. Similarly, in WO2017/211640 (Autostore Technology AS), the tilting device tilts the storage containers in the pick-up zone when the access station is to be operated with a picker, thereby providing the ergonomic benefits of tilting. The storage container is received at an entry position located on the entry conveyor at the rear of the access station. The entry position is configured for connection to another conveyor, for example a storage system conveyor, which conveys the storage container to and from the entry position. Upon entering the access station, the entry conveyor conveys the storage container in a conveying direction via a tiltable access conveyor to an exit conveyor in a pick-up zone at the front of the access station. Entry and exit of the storage container into the grid framework structure is via the rear of the access station. The entry and exit positions may each be connected to a storage system conveyor.

In a storage grid, the majority of the grid columns are storage columns, i.e., grid columns where storage containers are stored in a stack. However, the grid usually has at least one grid column that is not used for storing storage containers, but which comprises a location where container handling vehicles can drop off and/or retrieve storage containers so that they can be transported to a second location (not shown in the prior art figures) where the storage containers are accessible from outside the grid or can be transported from or to the grid. In the art, such locations are usually called "ports" and the grid column where the ports are located is sometimes called a "delivery column". The storage grid comprises two delivery columns. The first delivery column may comprise, for example, a dedicated drop port where container handling vehicles or baggage handling vehicles can drop off storage containers to be transported further through the delivery column to an access station or transfer station, and the second delivery column may comprise a dedicated removal port where container handling vehicles can remove storage containers transported from the access station or transfer station through the second delivery column. Storage containers are delivered to the access station via a first delivery column and exit the access station via a second delivery column. However, this arrangement not only removes one or more grid columns for storage of containers, but also limits the access stations that are tied to a particular grid column within the grid framework structure for supplying and retrieving storage containers to and from the access stations.

While the access stations described above are suitable for sourcing orders that are generally planned well in advance, e.g., several days prior to receipt of the customer order, no system is available for immediate sourcing of customer orders, i.e., within a few hours of receipt of the customer order. This is particularly true when the order comprises a small number of generally key items, e.g., bread or milk, and may also include impulse buying behavior of customers who have a tendency to purchase items without planning ahead. When customers make such purchase decisions on the spur of the moment, it is often triggered by emotions or feelings, i.e., they make unplanned purchases. Convenience stores, which typically stock a wide range of everyday items such as coffee, groceries, snack foods, confectionery, soft drinks, tobacco products, over-the-counter medicines, cosmetics, newspapers, and magazines, tend to be best placed to cater to such impulsive market demands. As the market for convenience stores and impulse purchases grows, access stations are therefore required to sourcing orders for immediate dispatch.

therefore,
i) It is flexible and can double as a pick-up station and/or a supply station;
ii) It is portable so that it can be retrofitted to any grid framework structure;
iii) An access station is needed that can work in conjunction with a pick or supply station in the storage system to source orders for immediate dispatch.

This application claims priority from GB application no. GB2008129.5, filed May 29, 2020, the contents of which are incorporated herein by reference.

The present invention alleviates the above problems by providing an inventory handling station assembly for a storage and retrieval system, the storage and retrieval system comprising:
a grid framework structure comprising a plurality of upright columns in one or more vertical planes, the upright columns being arranged such that one or more containers are stacked between the upright columns to form a plurality of grid columns vertically guided by the upright columns;
the plurality of upright columns are interconnected at their upper ends by a first set of grid members extending in a first direction and a second set of grid members extending in a second direction, the second set of grid members moving transversely in a substantially horizontal plane to the first set of grid members to form a grid having a plurality of grid cells or grid spaces;
the first set of grid members and the second set of grid members respectively support a first set of tracks and a second set of tracks for a load handling device to move one or more containers on the grid framework structure at an upper level of the grid framework structure;
wherein the inventory handling station assembly comprises:
i) a feeding zone comprising at least one vertical chute configurable to cooperate with at least one upright column, the at least one vertical chute having a first opening for receiving a container lowered by at least one baggage handling device through a grid cell and a second opening for allowing the container to exit the feeding zone;
ii) a buffer zone for vertically stacking one or more containers comprising at least one box lifting device, each of the at least one box lifting device being positionable to lift a container upwardly towards the grid such that, in use, the container can be retrieved by at least one baggage handling device;
iii) an access station intermediate the feeding zone and the buffer zone to allow access to one or more containers exiting the feeding zone;
iv) a conveyor system configured to transport one or more containers from the supply zone to the buffer zone via the access station.

For purposes of describing this invention, the terms "grid framework structure" and "framework structure" are used interchangeably to mean a three-dimensional structure for storage of containers. For purposes of describing this invention, the terms "grid" and "grid structure" are used interchangeably to mean a two-dimensional structure formed by a first set and a second set of horizontal members. The two-dimensional grid forms the top layer of the three-dimensional grid framework structure.

In comparison with the access stations integrated into the grid framework structure of the storage system described in the art, the inventory handling station assembly of the present invention is a separate stand-alone station capable of receiving a storage container or storage box from a baggage handling device operable on the grid framework structure. The grid framework structure can cooperate with the inventory handling station assembly such that one or more storage boxes or storage containers can be lowered into one or more chutes in the supply zone. Similarly, one or more box lifting devices in the buffer zone can vertically stack the storage boxes or storage containers before being removed by the baggage handling device operable on the grid. The drop port in the grid can cooperate with a delivery channel in the grid framework structure through which one or more storage containers are conveyed through a chute for supplying one or more storage containers to the supply zone. Similarly, the removal port in the grid can cooperate with a return channel in the grid framework structure through which one or more storage containers can be removed from the box lifting device in the buffer zone. The storage box or storage container is fed into the supply zone via at least one chute and transported to the buffer zone where it is vertically stacked for removal by a baggage handling device operable on the grid framework structure, i.e. on a track. For purposes of this invention, "vertical chute" and "chute" are used interchangeably throughout this specification to refer to the same feature.

The supply zone, access station, buffer zone, and conveyor system are all modular in construction and easily retrofittable to existing grid framework structures. One or more chutes allow a baggage handling device operable on the grid framework structure to lower the storage box under gravity and then transport the storage box to the access station, where an operator or robotic device can gain access to the contents of the storage container. The access station according to one aspect of the invention provides a flexible solution since it can be operated both as a removal station, where one or more items are removed from the storage container, and as a refill station (also known as a decant station), where one or more items are deposited into the storage container. For purposes of the present invention, the terms "baggage handling device" and "bot" are used interchangeably throughout this specification to denote the same feature.

The storage boxes or containers delivered to the supply zone are transported by the conveyor system through the access station to the buffer zone. The storage boxes or containers are paused at the pick-up station, where an operator selects the required items from the storage boxes or containers and places the items in the customer delivery box or container. In the buffer zone, a box lifting device lifts the storage boxes or containers towards the grid so that a baggage handling device operable on the upper level can retrieve the containers. This allows one or more storage boxes or containers to be stacked vertically in the buffer zone. Preferably, the box lifting device lifts the storage boxes or containers to the top level in the buffer zone above the conveyor system. More preferably, a baggage handling device operable on the upper level is able to grip the storage boxes or containers in the buffer zone and then lift the storage boxes or containers into the container receiving space of the baggage handling device.

Preferably, the conveyor system comprises an entrance conveyor unit, an exit conveyor unit, and at least one access conveyor unit, the entrance conveyor unit being disposed within the supply zone and arranged to convey the storage box or container from the second opening of the at least one vertical chute to the at least one access conveyor unit in a first direction or first conveying direction. The exit conveyor unit is disposed within the buffer zone and arranged to convey the storage box or container from the at least one access conveyor unit to the buffer zone in a second direction or second conveying direction, wherein the at least one access conveyor unit is arranged to convey the container from the supply zone to the buffer zone in a third direction or third conveying direction. The three conveyor units provide flexibility with respect to reducing the footprint of the inventory handling station assembly to convey one or more storage boxes or containers from the supply zone to the buffer zone via the access station in multiple conveying directions. For the purposes of this specification, the terms "conveyor" and "conveyor unit" are used interchangeably. The terms "direction" and "conveying direction" are used interchangeably and refer to the direction of conveyance of the conveyor or conveyor unit. The terms "first conveying direction" and "second conveying direction" are used for clarity from the terms "first direction" and "second direction" used above with respect to the first and second sets of grid members.

In one aspect of the invention, the entrance conveyor unit and the exit conveyor are arranged such that the first conveying direction of the entrance conveyor is opposite and parallel to the second conveying direction of the exit conveyor, and wherein the third conveying direction of the at least one access conveyor unit is substantially perpendicular to both the first conveying direction of the entrance conveyor unit and the second conveying direction of the exit conveyor, respectively. Here, the exit from the at least one chute of the supply zone and the entrance to the at least one box lifting device face the same direction, since both of them discharge or receive the storage box or storage container in equal but opposite directions, respectively. The at least one access conveyor unit is perpendicular to both the entrance conveyor unit and the exit conveyor unit. Thus, the storage box or storage container travels in a U-shaped direction through the conveyor system from the entrance to the supply zone through the access station and out to the buffer zone. As a result of this configuration, the storage box or storage container changes direction twice.

In another aspect of the invention, the conveyor system is arranged such that the first conveying direction of the entrance conveyor is perpendicular to both the second conveying direction of the exit conveyor and the third conveying direction of the at least one access conveyor. In this aspect of the invention, the storage boxes travel horizontally in an L-shaped direction from the entrance to the supply zone through the access station and then exit the access station into the buffer zone. As a result of this configuration, the storage boxes or storage containers change direction once as they enter the at least one access conveyor unit. Both configurations of the conveyor system maximize the throughput of the storage boxes or storage containers through the inventory handling station assembly over a relatively small footprint compared to a grid framework structure. To further increase the throughput of the storage boxes or storage containers through the inventory handling station assembly, the at least one box lifting device is arranged such that some storage boxes or storage containers travel in a U-shaped path and the rest travel in an L-shaped path, i.e., using both paths to increase the throughput of the storage boxes or storage containers through the inventory handling station assembly.

Preferably, the access station of the inventory handling station assembly of the present invention doubles as a supply station or a decant station where the inventory stored in the grid framework structure is replenished with fresh stock. In this configuration, the access station functions as a decant station where fresh stock is pumped into storage bins or containers, which arrive from the supply zone to the buffer zone and are then allocated to designated vertical storage columns or grid columns in the grid framework structure by a load handling device operable on the grid framework structure. In order to keep a record of the stock or inventory stored in the storage and retrieval system (i.e., the grid framework structure), preferably at least one access conveyor unit is equipped with a load cell for weighing the container. Preferably, the load cell is located below the at least one access conveyor unit. More preferably, the load cell is located below the at least one access conveyor unit such that the load cell is at the access station. When operated as a removal station, the load cell measures the weight of the storage container in the access station each time an item is removed from the storage container. Optionally, the one or more storage bins are provided with a label readable by a user interface to establish the identity of each of the one or more storage bins when it is paused at the pick station. This allows the stock control system to identify the storage bin or container and correlate the contents of the storage bin or container with the storage bins or containers stored in the grid framework structure. Optionally, the label of one or more of the storage bins may be a barcode, 1D barcode, 2D barcode, or QR code or RFID tag. A handheld scanner can be used to identify the identity of one or more of the storage bins, and the stock control system can correlate the contents of the one or more storage bins or containers with the identity of the storage bin or container itself. The weight reading is recorded together with the identity of the storage bin or container in an inventory or stock database, and the data is used to monitor and control the amount of stock in the storage system. For example, when the weight of a particular storage bin is less than its allocated predetermined weight, this provides the stock control system with information that the storage bin or container can take on more items. Preferably, the predetermined weight is between 15 kg and 50 kg, more preferably between 20 kg and 40 kg. An inventory or stock database is created that records the weight of each of the bins or containers and their contents within the grid framework structure. A stock control system is used to track the location of each bin or container within the grid framework structure and the contents of each of the bins. For purposes of this specification, the terms "inventory database" and "stock database" are used interchangeably.

When the access station is operated as a supply station, the load cells measure the weight of the storage bin or container each time stock is added to the storage container. The lifting mechanism of the load handling device with the gripping device is rated to lift a predetermined weight above which the lifting mechanism with one or more motors is placed under undue tension. To ensure that the weight of the storage bin or container does not exceed the predetermined required weight of the lifting mechanism, the load cells measure the weight of the storage container each time an item is added to the storage container at the access station.

Preferably, the at least one access conveyor unit comprises a plurality of adjacent conveyor units arranged to transport the storage box or container horizontally from the supply zone to the buffer zone via the access station. More preferably, each of the plurality of conveyor units is arranged to accommodate a single container, with at least one of the plurality of conveyor units comprising a load cell. Optionally, a work surface is arranged above the at least one access conveyor unit, the work surface having an opening allowing access to the contents of the storage container on the at least one access conveyor unit. Typically, the storage box or container is suspended on a particular conveyor unit of the at least one access conveyor unit.

At least one box lifting device in the buffer zone allows processed storage boxes or storage containers to be queued, preferably stacked vertically in the buffer zone before being picked up by the baggage handling device and deposited in their respective homes in the grid framework structure. For the purposes of the present invention, a processed storage box or storage container represents a storage box or storage container from which one or more items have been removed when the access station functions as a pick-up station, or loaded into when it operates as a decanting/feeding station. The at least one box lifting device prevents bottlenecking of storage boxes in the access station, especially at the work station, thereby reducing the throughput of storage boxes through the inventory handling station assembly. Preferably, the at least one box lifting device comprises two parallel arms engageable with the bottom wall of the storage container and a lifting mechanism arranged to move the two parallel arms vertically from the lowest level below the conveyor system to the highest level above the conveyor system, i.e. upwards towards the grid. This allows a luggage handling device operable on the grid, e.g., on a track, to subsequently retrieve the storage box or container waiting at the highest level by gripping the storage box or container and lifting it into the container receiving space of the luggage handling device. This allows the box lifting device, and thus the inventory handling station assembly, to be separated, e.g., disconnected, from the grid framework structure described above. The box lifting device allows one or more storage containers to be stacked vertically in a buffer zone as they pass through the access station. This increases the throughput of storage boxes through the access station, thus improving the efficiency of the inventory handling station assembly of the present invention to process or procure orders when used as a pick station and/or to replenish stock when used as a supply station.

To allow one or more storage boxes or containers to be stacked vertically in the buffer zone, preferably the two parallel arms are spaced apart by a distance greater than the width of the exit conveyor unit. This allows the two parallel arms to vertically descend past the exit conveyor unit in the buffer zone. Thus, when a storage box is lifted above the conveyor system and removed by a baggage handling device operable on the grid, the two parallel arms are commanded to descend past the exit conveyor unit in preparation for lifting another storage box or container waiting on the exit conveyor unit. The two parallel arms are capable of descending past a storage box or container waiting on the exit conveyor unit in the buffer zone to allow the lifting arms to position themselves downwards and engage the bottom wall of the storage box.

Preferably, the at least one vertical chute comprises at least two vertical guides for guiding the storage container vertically along the at least one vertical chute, each of the at least two vertical guides being receivable within a grid column of the grid framework structure. More preferably, each of the at least two vertical guides of the vertical chute comprises two right-angle plates extending along the length of the vertical chute. The at least two vertical guides of each of the at least one vertical chute help guide the storage box or storage container lowered by the load handling device onto the entrance conveyor unit in the supply zone. Preferably, the at least two vertical guides are spaced apart to cooperate with the grid columns, more specifically, the upright columns of the grid framework structure are arranged to cooperate with the at least two vertical guides. This allows a load handling device operable on the grid to be able to lower the storage box or storage container down the vertical chute through the grid cells, where the load handling device descends onto the entrance conveyor unit in the supply zone. Preferably, the at least one vertical chute comprises four vertical guides that cooperate with the four corners of the storage container. More preferably, the inventory handling station assembly includes a sidewall surrounding each of the at least one vertical chute.

In another aspect of the invention,
A) a storage and retrieval system, the storage and retrieval system comprising a grid framework structure, the grid framework structure comprising:
a) a plurality of upright columns arranged to form a plurality of grid columns in which one or more containers are stacked between the upright columns and vertically guided by the upright columns;
wherein a plurality of upright columns are interconnected at their upper ends by a first set of grid members extending in a first direction and a second set of grid members extending in a second direction, the second set of grid members moving transversely in a substantially horizontal plane to the first set of grid members to form a grid comprising a plurality of grid cells or grid spaces;
the first set of grid members and the second set of grid members respectively support a first set of tracks and a second set of tracks at an upper level of the grid framework structure for a load handling device to move one or more containers on the grid framework structure;
b) one or more containers stored within one or more grid columns, each of the one or more containers comprising one or more items having characteristic attributes;
c) one or more luggage handling devices remotely operated to move one or more containers stored within the grid framework structure, each of the one or more luggage handling devices comprising:
i) a wheel assembly for guiding the luggage handling device on the grid;
ii) a container receiving space located above the grid;
iii) a lifting device arranged to lift a single container from the stack into the container-receiving space,
Equipped with
B) A procurement/replenishment system is provided comprising an inventory handling station assembly of the present invention, and one or more load handling devices remotely operated to move one or more containers stored within the grid framework structure to and/or from the inventory handling station assembly.

For the purposes of the present description, the storage and retrieval system and the inventory handling station assembly are treated as separate components. However, the present invention is not limited to the inventory handling station assembly forming a separate part from the storage and retrieval system, and the inventory handling station assembly may form part of the storage and retrieval system. In both cases, the procurement/replenishment system comprises the storage and retrieval system and the inventory handling station assembly. The items may be any goods or grocery items. The goods or items may be bundled together in packages or bags for shipment to customers.

Preferably, the plurality of grid columns comprises a first set of grid columns and a second set of grid columns, wherein the first set of grid columns is arranged to store one or more containers in a stack, and wherein the inventory handling station assembly is arranged below the second set of grid columns such that, in use, a baggage handling device operable on an upper level of the grid framework structure can lower a container through the at least one grid column and down the at least one vertical chute, and the at least one box lifting device is arranged below the at least one grid column such that the at least one vertical chute and the at least one box lifting device are operable to lift a container to be removed through the at least one grid column into the container receiving space of the baggage handling cell.

Not all of the grid columns are used to store one or more containers between the upright columns, but rather comprise locations, also called ports, where a baggage handling device can drop off and/or retrieve a storage box or storage container, and the grid columns in which the ports are located may be referred to as delivery columns in which one or more storage boxes or storage containers are delivered to the supply zone. Similarly, the grid columns in which the ports are located for retrieval of storage boxes or storage containers may be referred to as recovery columns, i.e., one or more storage boxes are retrieved from the buffer zone. The first set of grid columns is arranged to form one or more vertical storage locations for one or more containers to be stacked between the upright columns, and the second set of grid columns is arranged to cooperate with at least one chute, and at least one box lifting device is arranged to receive and discharge one or more storage containers or storage boxes from the inventory handling station assembly. More specifically, the second set of grid columns comprises at least one delivery column and at least one recovery column. The at least one delivery column is configured to cooperate with at least one chute of the supply zone, and the at least one box lifting device is arranged to cooperate with at least one recovery column.

Preferably, the inventory handling station assembly is disposed below the second set of grid columns such that, in use, each of the at least one vertical chute and the at least one box lifting device is disposed below at least one grid column such that a baggage handling device operable on the upper level of the grid framework structure can lower a container through the first grid column down the at least one vertical chute and the at least one box lifting device is operable to lift a container to be removed through the second grid column into the container receiving space of the baggage handling cell. Preferably, the one or more vertical chutes are disposed to be received within one or more grid columns of the second set of grid columns. More preferably, the second set of grid columns is supported by a mezzanine floor. For example, grids from an adjacent grid framework structure are disposed to extend across the top of the mezzanine floor to create a service area therebelow for the removal station and/or the decanting station. The mezzanine floor is supported by one or more vertical support beams or I-beams.

Preferably, the procurement/replenishment system further comprises a bagging station, which comprises a table having a surface for supporting one or more bags, and a user interface in communication with the bagging station control system. In one aspect of the invention, one or more items of a given order removed from one or more storage bins or containers in the access station are transferred to one or more bags for delivery to a customer. At least one user interface in communication with the bagging station control system provides an input device for acknowledging the procurement that an item of the order has been removed from one or more storage bins or containers in the access station, i.e., acknowledging that an item of the order has been removed and loaded into a bag. This is repeated until all of the items of the order have been procured. Thus, each time one or more items are removed and loaded into a bag, an operator acknowledges the procurement of one or more items of the order by means of an input device, preferably a user interface in communication with the bagging station control system. The bagging station control system can be separate from the central control system for information about where to pick and deliver containers or totes within the grid framework structure and/or the control system that controls the amount of stock or inventory stored within the storage and retrieval system, or some or all of these functions can be combined within the same control system.

Preferably, the table is divided into one or more spaces or compartments by one or more partitions, each of the one or more spaces or compartments comprising a user interface. Multiple orders of one or more items can be separated on the table by one or more partitions. The partitions are used to separate one or more bags on the table surface. The separation can be based on different customer orders or based on attributes associated with the same order, e.g., frozen, refrigerated, or environmental items. Optionally, each of the one or more bags is a stand-alone bag. Acknowledgement that an item has been removed can be used to update a stock control system comprising an inventory database of remaining stock or inventory in the storage system.

One or more bags comprising the order of procured items can optionally be dispatched at the storefront for retrieval by the customer or a courier. Optionally, the one or more bags can be transferred to a plurality of electronically controllable lockers, each of which comprises a compartment sized to accommodate one or more bags. As is generally known in the art, electronically controllable lockers can work in conjunction with a range of e-commerce platforms, such as a click-and-collect model, where items purchased online are transported from a procurement or distribution center to a collection point accessible by the customer. Procured orders are stored in electronically controllable lockers accessible by the purchasing customer or a courier, as taught in GB patent application GB2004400.4 (Ocado Innovation Limited), the contents of which are incorporated herein by reference. Other examples of the use of electronically controllable lockers are taught in GB240712B (Bearbox Limited), EP1366442B1, and EP2375386A2 (ByBox Holdings Limited).

The baggage handling device preferably includes a control unit that receives control signals from a wireless communication unit of the control system or a central control system regarding information regarding where to pick and deliver the containers or totes within the grid framework structure. The control system may be separate from or the same control system that controls the amount of stock or inventory stored within the storage and retrieval system discussed above.

When used as a pick station, the control system is instructed to place and retrieve one or more storage containers that store one or more items of the order and deliver them to the supply zone of the inventory handling station assembly of the present invention, which are then transported along the conveyor system to the pick station where the items are removed from the storage container or the boxes are removed to the delivery container. The storage box or storage container with the remaining items is then returned to its allocated home in the grid framework structure. When the access station is used as a decanting or supply station to replenish the stock in the storage box or storage container, the baggage handling device is instructed to retrieve one or more storage containers from the allocated grid column or storage column. These may be empty storage containers or storage containers that store one or more items with a particular SKU (Stock Keeping Unit). Items such as grocery items have attributes that are characteristic of the item, such as manufacturer, brand, model, color, and/or size. Different items are distinguishable from one another by the characteristic attributes. One example of an attribute used by retailers to distinguish different stocks or inventory is the stock control unit or SKU.

The retrieved storage container or containers are moved to a decanting or dispensing station within the inventory handling station assembly where the items of a particular SKU are loaded into one or more storage containers or bins. The loaded storage bins or containers are then moved by a conveyor system to a buffer zone where they are stacked vertically until a load handling device or bot is free to return the storage bins or containers to their appropriate home within the grid framework structure, i.e., for storage within a grid or storage column.

Conventionally, when fulfilling an order for one or more items, a control system comprising one or more processors and a memory that stores instructions when executed by the one or more processors is configured to instruct one or more luggage handling devices to retrieve one or more storage bins or containers for each item in the order. Thus, when fulfilling an order for multiple different items, the control system is configured to retrieve multiple storage bins or containers for each of the multiple different items identified in the order. While this is appropriate when there are multiple luggage handling devices operating on a grid framework structure that are capable of retrieving multiple storage bins or containers to fulfill a single order of multiple items, the situation is different where multiple orders containing multiple items are required to be fulfilled within a tight time slot and/or there is a limited number of luggage handling devices available to retrieve the storage bins or containers required to fulfill the multiple orders. For example, there is a trend toward tighter time slots, e.g., immediate dispatch of orders within a few hours of receipt of the order, than in traditional online retail where orders are typically fulfilled over a period of several days. Convenience retail stores where orders are for staple grocery items such as milk, cheese, beverages, etc. are particularly prevalent.

In another aspect of the procurement/replenishment system of the present invention, the storage and retrieval system comprises:
one or more processors, whereby, in response to receiving a plurality of orders, each of the plurality of orders comprising one or more items, when executed by the one or more processors,
i) grouping or matching a plurality of orders based on at least one attribute of one or more items being common among the plurality of orders;
ii) generating a signal instructing a baggage handling device to retrieve a first container storing one or more items common to the plurality of orders;
iii) generating a signal instructing the baggage handling device to lower the first container down the at least one vertical chute through the at least one grid column;
iv) instructing the conveyor system to convey the first container to the access station such that one or more items common to the plurality of orders can be transferred to a plurality of delivery containers associated with the plurality of orders;
v) a control system comprising a memory storing instructions for instructing the conveyor system to convey the first container to the buffer zone.

For purposes of the present invention, an attribute of an item corresponds to a particular characteristic of an item, such as manufacturer, brand, type, color, and size, and is often identified by a characteristic stock control unit (SKU). For example, a particular brand of cheese is identified by a characteristic SKU. To reduce the number of trips one or more baggage handling devices must undergo to retrieve a plurality of storage bins or containers to fulfill a plurality of orders, the control system includes one or more processors and a memory storing instructions that, when executed by the one or more processors in response to receiving a plurality of orders, cause the one or more processors to group or match the plurality of orders based on at least one attribute of one or more items being common among the plurality of orders. In the case where the one or more items are grocery items, the one or more grocery items are common or shared among the plurality of orders. Here, the plurality of orders can be matched or grouped based on each of the plurality of orders comprising a particular grocery item, e.g., an order of cheese of a particular attribute being shared among the plurality of orders. The control system instructs the package handling device to retrieve a single bin or container if the contents of the bin or container comprise a grocery item, e.g., cheese, with a particular attribute, such that the contents of the bin or container are shareable among multiple orders.

By grouping or matching the multiple orders based on at least one attribute of one or more items being common among the multiple orders, items in a single storage bin or storage container can be shared among the multiple orders. This removes the need to repeatedly retrieve the same storage bin or storage container from the grid framework structure for multiple different orders. By matching or grouping the multiple orders based on at least one attribute of one or more items being common among the multiple orders, the control system can generate a signal to instruct the baggage handling device to retrieve a first container storing one or more items common to the multiple orders, instruct the baggage handling device to lower the first container down at least one vertical chute through at least one grid column, and generate a signal to instruct the conveyor system to convey the first container to an access station such that the one or more items common to the multiple orders are shareable among multiple delivery containers associated with the multiple orders. For example, the delivery container can be a bag. By grouping or matching multiple orders based on at least one attribute of one or more items being common among the multiple orders, items from a single storage bin or container can be shared among multiple delivery containers, e.g., picked simultaneously, thus reducing the processing time for procuring multiple orders. For purposes of the present description, a grid column in which at least one vertical chute is installed is referred to as a delivery column, and a grid column in which at least one box lifting device is installed is referred to as a collection column.

Preferably, the control system includes one or more processors configured to:
v) generating a signal instructing the baggage handling device to retrieve a second container storing one or more items common to the plurality of orders;
vi) generating a signal instructing the baggage handling device to lower the second container through the at least one grid column and down the at least one vertical chute;
vii) instructing the conveyor system to convey a second container to the access station such that one or more items common to the plurality of orders can be transferred to a plurality of delivery containers associated with the plurality of orders;
viii) further configured to execute instructions to instruct the conveyor system to convey the second container to the buffer zone.

Preferably, the control system is further configured to cause the one or more processors to execute instructions to generate signals instructing one or more baggage handling devices to retrieve the first container and the second container from the buffer zone via at least one retrieval column.

To further increase the efficiency of fulfillment of the multiple orders, preferably the first container comprises one or more items of a first attribute and one or more items of a second attribute, where the one or more items of the first attribute and/or the one or more items of the second attribute are common among the multiple orders. In this case, the control system can match or group multiple or multiple orders of multiple different items based on the multiple different items or at least one item of each of the multiple orders being common or shared among the multiple orders. By storing multiple different items in a single storage box or storage container, where each of the different items has a distinctive attribute, the control system can place and retrieve a single storage box or storage container whose contents are shareable among the multiple orders. This increases the likelihood that the contents of the storage box or storage container are shareable among the multiple orders. Thus, fewer baggage handling devices are required to retrieve a storage box or storage container to fulfill an order of one or more items.

Preferably, the storage and retrieval system of the procurement/replenishment system further comprises an order database comprising data associated with a plurality of orders for one or more items;
Here, the control system is configured to access the order database to group or match a plurality of orders based on at least one attribute of one or more items being common among the plurality of orders.

Preferably, the storage and retrieval system of the procurement/replenishment system further comprises a stock database comprising data of at least one attribute of one or more items.

To increase the efficiency of processing the storage boxes or containers through the inventory handling station assembly, at least one box lifting device comprises a first box lifting device and a second box lifting device, and the control system is configured to command the conveyor system to convey the container to the first box lifting device or the second box lifting device depending on the occupancy of the first box lifting device and the second box lifting device. More preferably, the occupancy of the first box lifting device and the second box lifting device is determined by one or more sensors in the first box lifting device and the second box lifting device. For example, the one or more sensors may be photoelectric sensors (through beam sensors or reflective sensors or proximity sensors) based on transmitting and receiving light. In response to a signal from the one or more sensors in the box lifting device, the control system can determine the occupancy of the box lifting device and redirect the storage box or container to the second box lifting device, if needed, to provide some slack in the buffer zone. This may be through a change in the orientation of the storage box or container in the buffer zone.

The present invention also provides a method of fulfilling a plurality of orders with a procurement/replenishment system of the present invention, each of the plurality of orders comprising one or more items, the method comprising:
i) grouping or matching a plurality of orders comprising one or more items based on each of the plurality of orders having at least one attribute in common;
ii) identifying a first container comprising one or more items having at least one attribute common to each of the plurality of orders;
iii) instructing one or more baggage handling devices to retrieve a first container storing one or more items from the grid framework structure;
iv) lowering the first container via at least one vertical chute into a feeding zone;
v) conveying the first container to an access station;
vi) transferring one or more items from the first container to a plurality of delivery containers associated with a plurality of orders;
vii) conveying the first container to a buffer zone;
viii) lifting the first container towards the grid;
and ix) instructing one or more baggage handling devices operable on the grid to retrieve the first container from the buffer zone and return the first container to the grid framework structure.

When an order for one or more items is received, or when it is otherwise desired to retrieve items required to fully or partially fulfill an order, a control system associated with the inventory handling station assembly of the present invention can request retrieval to the inventory handling station assembly of any storage boxes or storage containers containing the desired items to be retrieved at the access station functioning as a retrieval station. Such storage boxes or storage containers can be retrieved from one or more stacks in the corresponding portion of the grid framework structure and delivered to the inventory handling station assembly by being lifted by an overhead baggage handling device operable on the grid and delivered to a port, where they can be lowered below a delivery column of the grid framework structure. At least one chute of the supply zone is configured to cooperate with the delivery column to receive the storage boxes. Similarly, at least one box lifting device is configured to cooperate with the retrieval column to raise the storage boxes or storage containers to a level to be retrieved by the baggage handling device and thus exit the buffer zone.

The multiple orders may comprise a first order of one or more items and a second order of one or more items. The first bin or container comprises one or more items having common or shared attributes between the first order and the second order. The method includes:
i) identifying a second container comprising one or more items having at least one attribute common to each of the plurality of orders;
ii) instructing one or more baggage handling devices to retrieve a second container storing one or more items from the grid framework structure;
iii) lowering the second container via at least one vertical chute into the feeding zone;
iv) conveying a second container to an access station;
v) transferring one or more items from the second container to a plurality of delivery containers associated with the plurality of orders;
vi) conveying the second container to a buffer zone;
vii) lifting the second container towards the grid;
and viii) instructing one or more baggage handling devices operable on the grid to retrieve the second container from the buffer zone and return the second container to the grid framework structure.

Preferably, the delivery container or box is a bag. The method further comprises the step of transferring one or more items from the one or more containers to the one or more bags. Optionally, the one or more bags comprising the fulfilled order for the one or more items are transported to one or more electronically controllable lockers where the bags are stored in one or more compartments for retrieval by a customer or a courier.

Another aspect of the present invention is a method of stocking or replenishing one or more items by a procurement/replenishment system according to the present invention, comprising the steps of:
i) transferring a stock of one or more items to one or more receptacles in an access station;
ii) moving one or more containers containing a stock of one or more items into the buffer zone;
iii) lifting one or more containers containing a stock of one or more items towards a grid within the buffer zone;
and iv) commanding one or more baggage handling devices to retrieve one or more containers containing a stock of one or more items from the buffer zone and transport the one or more containers to the grid framework structure.

In this aspect of the invention, the access station of the inventory handling station assembly of the invention doubles as a replenishment station. Palletized items or other batches of items arrive at the replenishment station. For example, the pallet may be removed from a truck and moved to the inventory handling station assembly that doubles as a stock station or replenishment station. Upon removal or unpacking of any packaging, the one or more items are transferred to one or more storage boxes or storage containers in the access station. Depending on the type of item, as discussed above, each of the one or more items is classified with a specific SKU or stock storage unit. As is commonly known in the art, SKUs or stock storage units are used by retailers to identify and track their inventory or stock. An SKU is a unique code consisting of letters and numbers that identifies characteristics for each item, such as manufacturer, brand, model, color, and size. This can be recorded in a bar code. Items of a particular type are grouped together according to the SKU. In one aspect of the invention, a load handling device operable on a grid framework structure is instructed to retrieve a storage box from an upright column in the grid framework structure. This may be an empty storage box or container, or a partially empty storage box or container storing items of the same type or with the same SKU as the palletized item. The method further comprises the step of retrieving one or more containers from the grid framework structure, lowering the one or more containers via at least one vertical chute to a supply zone, and then commanding one or more load handling devices to transport the one or more containers from the supply zone to an access station, which also serves as a stock station. In another aspect of the invention, fresh storage boxes or containers can be introduced into the grid framework structure via the access station. In both cases, one or more items are loaded into the storage box or container and fed into the grid framework structure via a buffer zone. Preferably, the method further comprises the step of weighing the one or more containers in the access station. This is so that the weight of the storage box or container does not exceed a predetermined weight necessary to safely lift the storage box or container and/or the lifting device of the load handling device in the buffer zone. Typically, the lifting device of the load handling device, which comprises one or more motors, is rated to lift a predetermined weight above which the lifting device will struggle to lift the container. The weight of each of the storage boxes or containers in the access station is measured by a weighing cell, e.g., a load cell. Optionally, the conveyor system is instructed to prevent the storage box or container from being conveyed to the buffer zone if the weight of the storage box or container exceeds a predetermined weight.

Further features and aspects of the present invention will be apparent from the following detailed description of exemplary embodiments, taken in conjunction with the drawings.

1 is a schematic diagram of a grid framework structure according to known systems; FIG. 2 is a schematic diagram of a top-down view showing a stack of boxes arranged within the framework structure of FIG. 1 . 1 is a schematic diagram of a system of known baggage handling devices operating on a grid framework structure. FIG. 2 is a schematic perspective view of a luggage handling device showing a lifting device gripping a container from above. 5A is a schematic perspective cutaway view of the luggage handling device of FIG. 4, showing a container receiving space of the luggage handling device, and FIG. 5B is a schematic perspective cutaway view of the luggage handling device of FIG. 4, showing a container that fits into the container receiving space of the luggage handling device. 2 is a front perspective view of an inventory handling station assembly according to one embodiment of the present invention; FIG. 7 is a perspective view of the framework of the inventory handling station assembly shown in FIG. 6; FIG. FIG. 2 is a top view of a conveyor system in accordance with one embodiment of the present invention. FIG. 4 is a top view of a conveyor system according to another embodiment of the present invention. 1 is a top plan view of a procurement center incorporating a mezzanine level to house inventory handling station assemblies in accordance with an embodiment of the present invention. 4 is a flow chart illustrating the operational steps of the removal station, in accordance with one embodiment of the present invention. 4 is a flow chart illustrating the operational steps of a replenishment station, according to one embodiment of the present invention. 1 is a block diagram illustrating components of a procurement system according to one embodiment of the present invention. 2 is a perspective view of an inventory handling station assembly incorporating a bagging station according to one embodiment of the present invention; FIG. FIG. 14b is a rear perspective view of the inventory handling station assembly shown in either FIG. 6 or FIG. 14a. 4 is a flow chart illustrating the computational steps in matching or grouping multiple orders according to one embodiment of the present invention. 1 is a perspective view of a storage box or container according to one embodiment of the present invention; 2 is a perspective view of a storage box or container according to another embodiment of the present invention;

The present invention is in contrast to known features of storage systems, such as the grid framework structure and baggage handling devices described above with reference to Figures 1-5. In a typical procurement center, a wide variety of items, such as grocery items, are stored in storage bins or containers, which are stored in one or more stacks in a grid framework structure, more specifically in a grid column. A grid column is formed by a number of upright columns arranged as vertical storage locations. Individual containers may be stacked in vertical layers, and their location in the grid framework structure or "hive" may be indicated to represent the location of the baggage handling device or container and the container depth (e.g., container in (X,Y,Z), depth W) using coordinates in three dimensions. Similarly, locations within the grid framework structure may be depicted in two dimensions to represent the location of a baggage handling device or container and the container depth (e.g., a container at (X,Y), depth Z). For example, Z=1 identifies the top layer of the grid framework structure, i.e., the layer immediately below the rail system, Z=2 is the second layer below the rail system, and so on down to the bottom layer, which is the lowest layer of the grid framework structure. The majority of the grid columns within the grid framework structure are storage columns.

The order fulfillment system comprises a box or container filling station, a storage and retrieval system, a plurality of stations for order retrieval, an order container handling and sorting system, and a dispatch facility. Details of the order fulfillment system are described in PCT/IB2014/062165 (Ocado Innovation Limited), the details of which are incorporated herein by reference. In order fulfillment systems such as those described in PCT/IB2014/062165 (Ocado Innovation Limited), individual containers are stored in the storage and retrieval system and may contain one or more items, which may be identical. The storage and retrieval system comprises a grid framework structure in which storage boxes or containers are stored in grid columns.

To retrieve an order with different items, it is often necessary to retrieve items from multiple source containers. Such containers can be retrieved from a storage and retrieval system and transported to a desired system for order retrieval. The specific container required for fulfillment of the order is accessed by a robotic baggage handling device operable on a grid framework structure. The baggage handling device preferably comprises a control unit that receives control signals from a wireless communication unit of the control system or a central control system regarding information regarding where within the grid framework structure the storage bin or storage container should be retrieved and delivered. The control system controls the operation of one or more baggage handling devices operable on the grid framework structure and comprises one or more processors, memory (e.g., read-only memory and random access memory), and a communication bus. The memory may be any storage device generally known in the art, including, but not limited to, RAM, computer readable media, magnetic storage media, optical storage media, or other electronic storage media used to store data and accessible by one or more processors.

At least one grid column is not used for storing containers and typically comprises a location where a load handling device can drop off and/or retrieve storage containers or storage bins to and from a pick-up or supply station external to the grid framework structure. In the art, such locations are typically referred to as "ports" and correspond to grid cells where storage bins or storage containers are dropped off or retrieved. Depending on whether the port is installed for the drop-off or pick-up of storage containers, the grid column in which the port is installed may be referred to as a "delivery column" installed at the drop-off port and a "recovery column" installed at the pick-up port.

As is commonly known in the art, items in inventory are identified and tracked by unique codes called SKUs (Stock Keeping Units), which identify distinctive attributes for each item in inventory, such as manufacturer, brand, type, color, and size, and help distinguish different types of items in inventory or stock, for example, a particular brand of cheese. When a retailer takes delivery of its stock, it counts the amount of each SKU it has. Palletized items or other batches of items arrive at a bin filling or refill station. For example, a pallet of items may be removed from a truck or other transportation at an order processing/procurement center and moved to one or more storage bins or storage receptacle filling stations. Typically, a filling station comprises a trolley, conveyor, trolley, etc. for holding multiple storage bins or storage receptacles. The filling station may accept either empty or partially filled storage receptacles. Once the desired stock of a storage receptacle or storage receptacle is completed, the storage receptacle may be transferred, for example by a conveyor, to storage in the storage and retrieval system and stored therein until needed for fulfillment of an order. For example, a storage box or container may be carried to a drop port by an overhead baggage handling device operable on a grid framework structure and lowered to a pick-up station where one or more of the items of the order can be picked up to a destination or delivery container.

The storage control and communication system is used to monitor inventory and track the location of each storage bin or container within the grid framework structure and the contents of each of the storage bins or containers. The storage control and communication system may also form part of or communicate with a control system or central control system for controlling a load handling device instructed to retrieve a desired storage bin or container from within the grid framework structure and deliver it to a desired location or drop port on the grid framework structure at a desired time without colliding with other load handling devices operable on the grid framework structure.

In one embodiment of the present invention, the pick-up station doubles as a refill station. For the purposes of the present invention, the pick-up/refill station may be referred to as an inventory handling station assembly having an access station that can function as both a pick-up station and/or a refill station. The inventory handling station assembly cooperates with the storage and retrieval system to provide a procurement system for the procurement of one or more orders. In the embodiment shown in FIG. 6, the inventory handling station assembly 60 comprises one or more chutes 62 forming a supply zone 64, an access station 66, and one or more box lifting devices 68 forming a buffer zone 70. By reference to its name, the one or more chutes 62 allow a load handling device operable on the grid framework structure 14b to lower a storage box or storage container without assistance from the one or more chutes 62. This may be subject to the action of gravity if the storage box or storage container is allowed to lower the chute 62 under the weight of the storage box or storage container and/or is lowered by a lifting or winch mechanism of the load handling device.

One or more items are removed from or loaded into one or more storage boxes or containers in the access station 66 depending on whether the access station 66 functions as a removal station or a refill station. The one or more chutes 62 and the one or more box lifting devices 68 are arranged to cooperate with the grid framework structure 14b described above. The grid framework structure 14b comprises a plurality of upright columns in one or more vertical planes and arranged to form a plurality of vertical locations or vertical grid columns 15 for the containers to be guided vertically by the plurality of upright columns. The plurality of vertical grid columns extend across the one or more chutes 62 and the one or more box lifting devices 68 of the inventory handling station assembly 60 (see FIG. 6). The plurality of upright columns are interconnected at their upper ends by a first set of grid members extending in a first direction and a second set of grid members extending in a second direction, the second set of grid members moving transversely to the first set of grid members in a substantially horizontal plane to form a grid comprising a plurality of grid cells or grid spaces. The grid cells are sized to allow storage boxes to enter or exit the grid cells. The grid cells include drop ports and removal ports arranged to cooperate with one or more chutes 62 and one or more box lifting devices 68, respectively. More specifically, the grid columns in which the drop ports (delivery column 15b) and removal ports (return column 15c) are located are arranged to cooperate with one or more chutes 62 and one or more box lifting devices 68, respectively, of the inventory handling station assembly 60.

The inventory handling station assembly 60 of the present invention is arranged as a stand-alone station that is easily retrofitted to an existing grid framework structure, and therefore can cooperate with the grid running overhead. For example, at least one chute and at least one box lifting device can be aligned with one or more grid columns so that the storage container or storage box can easily pass through the grid column to the at least one chute. Similarly, the storage box or storage container can be lifted from at least the box lifting device and passed through the grid column. The inventory handling station assembly 60 may be of modular construction in which the supply zone 64, the access station 66, and the buffer zone 70 can be formed as modules that are assembled together. As a result, the inventory handling station assembly 60 does not have the reliability of being connected to the grid framework structure, but can be formed as a separate part of the grid framework structure. The versatility of the inventory handling station that is retrofitted to an existing grid framework structure allows the inventory handling station assembly to be assembled in a variety of centers, from large distribution centers that handle thousands of items to small convenience stores that meet the demands of a smaller percentage of orders. For example, the inventory handling station assembly may form part of a back-end set-up where orders are filled at the back-end before being dispatched to a customer or courier or at a storefront.

6 and 7, the inventory handling station assembly 60 comprises a freestanding framework that divides the inventory handling station assembly into a supply zone 64, a buffer zone 70, and an access station 66. The one or more chutes 62 of the supply zone 64 comprise at least two vertical guides 72 that are receivable within the grid column 15b and are positioned to guide the storage boxes or containers through the drop ports to the supply zone 64 below the grid column 15b. For the purposes of definition, the grid column in which the drop ports in the grid are located is referred to as the delivery column 15b. Similarly, the grid column in which the pick-up ports in the grid are located is referred to as the collection column 15c. In a particular embodiment of the invention, each of the one or more chutes 62 comprises four guides 72 that are receivable within the grid column 15b of the grid framework structure 14b. Each of the guides 72 comprises two orthogonal plates (two container guide plates at right angles to each other) that extend longitudinally along the length of the chute. As shown in FIG. 7, one end of each of the guides extends to and is positioned to abut the grid column or delivery column 15b with respect to the four upright columns that make up the grid column. Thus, a storage box or storage container lowered below the drop port is guided by the guide 72 through the delivery column 15b (where the drop port is located) to the chute 62 of the supply zone 64.

Sidewalls or panels 74 are attached to the exterior of at least two vertical guides 72 to surround the vertical chute 62. The sidewalls or paneling 74 provide a shield for an operator from one or more storage boxes or containers descending down the chute 62 in the feed zone 64. In the particular embodiment shown in FIG. 7, a first portion of the guide is covered by the sidewall or panel 74 and a second portion of the guide is received within the delivery column 15b. This allows the sidewall or panel 74 to provide a seamless transition from the delivery column 15b to the chute 62 of the inventory handling station assembly 60.

The conveyor system 76 transports the storage boxes or containers from the supply zone 64 to the access station 66 and then to the buffer zone 70 where the storage boxes or containers are stacked vertically for removal by a baggage handling device operable on the grid framework structure 14b and return to either its original destination in the grid framework structure or a new destination in the grid framework structure. In a particular embodiment of the invention, the conveyor system 76 comprises a plurality of conveyor units, namely an entrance conveyor unit 78, at least one access conveyor unit 80, and an exit conveyor unit 82, and is arranged to transport the storage boxes or containers from the supply zone 64 to the buffer zone 70 via the access station 66. The storage boxes or containers are paused at the access station 66, which functions as a removal station or a refill station. The conveyor units are arranged adjacent to each other or connected to each other such that the storage boxes are transported from one conveyor unit to an adjacent conveyor unit as they proceed along the conveyor system 76.

In an embodiment of the present invention, the entrance conveyor unit 78 is disposed within the supply zone 64, and more specifically, the entrance conveyor unit 78 is disposed within each of the one or more chutes 62. As shown in FIG. 7, the entrance conveyor unit 78, the at least one access conveyor unit 80, and the exit conveyor unit 82 are on the same level. Similarly, the exit conveyor unit 82 is disposed within the buffer zone 70. Each conveyor unit may comprise any suitable arrangement of belts, chains, and/or rollers well known in the art of conveyor systems. In the particular embodiment of the present invention shown in FIG. 7, the entrance conveyor unit 78, the at least one access conveyor unit 80, and the exit conveyor unit 82 comprise a plurality of roller conveyors for conveying the storage box or storage container along a path on the conveyor system 76. The entrance conveyor unit 78, the at least one access conveyor unit 80, and the exit conveyor unit 82 are disposed such that the path or conveying direction of the storage box or storage container can follow a U-shaped path as shown in FIG. 8 or an L-shaped path as shown in FIG. 9. As shown in FIG. 7, the conveyor system 76 is mounted on a roller frame. The entrance conveyor unit 78 and the exit conveyor unit 82 are positioned to accommodate a single storage bin above.

8, the path or conveying direction of the entrance conveyor unit 78 may be parallel and opposite to the path or conveying direction of the exit conveyor unit 82, such that the path or conveying direction of the at least one access conveyor unit 80 is perpendicular or orthogonal to the paths or conveying directions of both the entrance conveyor unit 78 and the exit conveyor unit 82. In other words, the storage box or storage container travels in a U-shaped path along the conveyor system 76, i.e., the storage box changes direction twice along the conveyor system. Optionally, as shown in FIG. 9, the path or conveying direction of the exit conveyor unit 82 extends longitudinally in the same conveying direction of the at least one access conveyor unit 80, i.e., the exit conveyor unit 82 is an extension of the at least one access conveyor unit 80. Here, the path or transport direction of the entrance conveyor unit 78 is perpendicular or orthogonal to the path or transport direction of both the at least one access conveyor unit 80 and the exit conveyor unit 82, such that the storage box or container travels in an L-shaped path along the conveyor system 76, i.e. changes direction once as the storage box or container travels from the supply zone to the buffer zone. In a particular embodiment of the invention shown in Figures 6 and 7, the conveyor system is arranged such that the path or transport direction of the storage box can follow both a U-shaped path and an L-shaped path along the conveyor system 76. The combination of a U-shaped path and an L-shaped path allows multiple storage boxes or containers to be queued in the buffer zone 70 before being lifted towards the grid for subsequent collection by a baggage handling device operable on a track or rail on the grid. This allows multiple storage boxes or containers to be processed through the access station 66, compared to the prior art solutions. The combination of U-shaped and L-shaped paths allows for a relatively narrow inventory handling station assembly for handling multiple storage bins or containers at the access station 66, as compared to prior art solutions.

At least one access conveyor unit 80 extends between the entrance conveyor unit 78 and the exit conveyor unit 82 and may comprise multiple conveyor units arranged adjacent to one another in a horizontal plane such that the storage boxes or storage containers are transported from one conveyor unit to an adjacent conveyor unit along the access conveyor unit 80. In the particular embodiment shown in Figs. 6 and 7, at least one access conveyor unit 80 comprises six conveyor units. Alternatively, at least one access conveyor unit 80 may be a single conveyor unit extending between the entrance conveyor unit 78 and the exit conveyor unit 80. Typically, at least one or more of the rollers of the access conveyor unit 80 and, optionally, the entrance conveyor unit 78 and/or the exit conveyor unit 82 are provided with an integrated drive motor (not shown), and the remaining rollers may be connected to the drive rollers by belts (not shown) or may be passive.

An additional conveyor unit 84 (see Figs. 8 and 9) positioned adjacent to the entrance conveyor unit 78 and/or the exit conveyor unit 82 is integrated into at least one access conveyor unit 80. In a particular embodiment of the invention, the additional conveyor unit or direction change conveyor unit 84 comprises one or more rollers or belts or chains arranged laterally disposed between or interfitting with the rollers of the at least one access conveyor unit and arranged to be driven transversely in the conveying direction (see arrows in Figs. 8 and 9) of the at least one access conveyor unit. The additional conveyor unit or direction change conveyor unit 84 is lowered or raised by a lifting mechanism (not shown) relative to the rollers of the at least one access conveyor unit 80 such that in the raised position, the direction change conveyor unit 84 contacts the storage box and causes the direction change conveyor unit 84 to pull or draw the storage box from the entrance conveyor unit 78 onto the at least one access conveyor unit 80. This is indicated by the arrows in Figs. 8 and 9. Once on the at least one access conveyor unit 80, the storage box or conveyor can then be transported along the at least one access conveyor unit 80 through the access station 66 to the buffer zone 70. A similar setup is shown in the buffer zone 70, where a second redirection conveyor unit 84 is positioned to transport the storage box or storage container onto an exit conveyor unit 82 in the buffer zone 70. Although a particular embodiment describes a lifting mechanism that engages the redirection conveyor unit 84 with the storage box on the entrance conveyor unit 78 and the exit conveyor unit 82, other redirection conveyor units commonly known in the art of conveyor systems, such as conveyor balls, rail-mounted trolleys, etc., are applicable in the present invention.

As shown in FIG. 6, the access station 66 comprises a work surface 86 above the at least one access conveyor unit 80 and having an opening 88 that allows an operator to gain access to a storage box or storage container on the at least one access conveyor unit 80 below. As discussed above, the operator can retrieve or feed a desired item to or from a storage box in the access station 66 depending on whether the access station 66 functions as a removal station or a refill station. If the at least one access conveyor unit 80 comprises multiple conveyor units, an access conveyor unit 90 (shown by light shading in FIGS. 8 and 9 ) disposed below the opening 88 in the work surface 86 comprises a weighing cell, or the weighing cell can be positioned anywhere along the at least one access conveyor unit 80. The weighing cell is connected to the at least one access conveyor unit 80 and is positioned to weigh a storage box in the access station 66. The weighing cell may be a load cell or any other weighing cell commonly known in the art. A control panel (not shown) at the front of the access station 66 displays the weight of the bin as items are removed from or loaded into it. For example, when operated as a pick station, the weigh cell measures the weight of the bin or container as one or more items are removed from the bin. The storage control and communication system discussed above is used to monitor an inventory or stock of specific items by recording the weight of the bin as items are removed from the bin. This allows the storage control and communication system to track the contents of each of the bins or containers stored within the grid framework structure. When the contents of a particular bin or container with a particular attribute or SKU are running low, as measured by the weigh cell and recorded by the storage control and communication system, a notification is sent to an operator, for example via the control panel, to refill the bin.

When operated as a refill or supply station, fresh stock is loaded into storage bins in the access station 66 before being transferred to and stored in the grid framework structure until required for fulfillment of an order. The storage bins or containers may be transported to a drop port by an overhead baggage handling device operable on the grid framework structure 14b and lowered to the inventory handling station assembly 60 where one or more of the items can be loaded into the storage bins or containers at the access station 66. The storage bins or containers are weighed at the access station 66 each time an item is loaded into the storage bin. The weighing scales prevent the storage bins from being overloaded in the access station 66, as this would prevent the box lifting device and/or lifting mechanism of the baggage handling device in the buffer zone 70 from being able to lift the storage bin or container. The lifting mechanism of the baggage handling device and/or the motor of the box lifting device are rated to carry a predetermined weight. Once the predetermined weight is reached, a display on the control panel provides notification to the operator, i.e., via the display panel, that the weight of the particular storage box or container has been reached and no further items can be added to the storage box before it is transported to the buffer zone 70. Additionally or alternatively, the lifting mechanism of one or more box lifting devices can include a weighing cell that weighs the storage box or container as it is lifted towards the grid framework structure 14b.

To prevent one or more storage boxes or containers from getting stuck at the access station 66, the buffer zone 70 includes one or more box lifting devices 68 to allow one or more storage boxes to be stacked vertically within the buffer zone 70. The box lifting device 68 includes a lifting arm and a lifting mechanism. In a particular embodiment of the present invention, the box lifting device 68 includes a pair of lifting arms 92, i.e., two lifting arms 92. The space between the lifting arms 92 is wide enough to allow the exit conveyor unit 82 to pass between the lifting arms 92 as the lifting arms 92 descend past the exit conveyor unit 82. In use, the lifting arms 92 descend to a lowest level below the exit conveyor unit 82 so that the lifting arms 92 can engage the bottom wall of the storage box on the exit conveyor unit. The storage box or container is lifted from its lowest position on the exit conveyor unit 82 to its highest position toward the grid framework structure 14b such that the storage box is vertically spaced from the exit conveyor unit 82. This allows the second storage box or container to enter the exit conveyor unit 82 and be stacked vertically below the storage box or container above it. The topmost storage box waits until a baggage handling device operable on the grid at the upper level can retrieve it through the removal port via the retrieval column 15c. More specifically, the gripping device of the baggage handling device can grip the storage box or container at the topmost level and lift it into the container receiving space of the baggage handling device. The sensor detects the retrieval of the storage box at the topmost level, which lowers the lifting arm 92 below the second storage box or container resting on the exit conveyor unit 82 and then sends a signal to the control system or controller to be lifted to the topmost level, allowing the third storage box or container queued in the buffer zone to enter the buffer zone 70 via the exit conveyor unit 82. Once the storage box or container has entered the buffer zone 70, the entire process is repeated.

The box lifting device 68 can include multiple pairs of lifting arms 92 that are vertically spaced apart to allow multiple storage boxes to be stacked vertically at different heights within the buffer zone 70. For example, a first pair of lifting arms can be positioned to lift a first storage box to a first height, a second pair of lifting arms can be positioned to lift a second storage box to a second height, and so on. This allows multiple storage boxes to be stacked vertically at different heights within the buffer zone 70. In addition, one or more box lifting devices 68 can be positioned adjacent to each other. To save space and reduce the footprint of the inventory handling station assembly 60, the first box lifting device can be positioned at the end of at least one access conveyor unit 80 so that the storage box or storage container can be transported to the first box lifting device along the same path of the access conveyor unit 80. When the first box lifting device is fully occupied, the storage box can be commanded to change direction to the adjacent second box lifting device, for example, perpendicular to the conveying direction of the at least one access conveyor unit. This can be achieved by controlling the direction changing conveyor unit 84 adjacent to the buffer zone 70 to convey the storage box to the second box lifting device. Here, the control system or a separate controller monitors the occupancy of the first box lifting device and the second box lifting device, and depending on their occupancy, decides whether to convey the storage box to the first box lifting device or the second box lifting device. The occupancy of the box lifting device 68 is determined by one or more sensors to detect the presence of a storage box or storage container in the box lifting device. Examples of sensors include, but are not limited to, proximity sensors such as optical sensors.

Having multiple box lifting devices 68 allows for a greater throughput of storage boxes or containers through the inventory handling station assembly 60. In both cases, the storage boxes follow either a U-shaped path or an L-shaped path from the access station 66 depending on whether the first or second box lifting device is occupied. The number of box lifting devices 68 is not limited to two, and the exit conveyor units 82 can be positioned to allow multiple box lifting devices 68 to be at the receiving end of at least one access conveyor unit 80.

Similar to the chute(s) 62 in the supply zone 64, the box lifting device(s) 68 includes at least two guides 94 that guide the storage box or container vertically to be lifted by the lifting arm 92. In the particular embodiment shown in FIG. 7, four guides 94 are shown with a portion of the guide at the highest level received in the grid column or collection column 15c where the removal port is located. Similarly, a bracket 96 can be used to connect the highest portion of the box lifting device 68 with the collection column 15c of the grid framework structure 14b (see FIG. 7). The bracket 96 includes a guide that guides the storage box or container to the collection column. This allows the box lifting device 68 to be a separate part of the grid framework structure described above - and therefore to be retrofitted to an existing grid framework structure. The box lifting device(s) 68 includes a side wall or panel 74 that surrounds the box lifting device 68 and is attached to the exterior of at least a portion of the guide to prevent the components of the box lifting device 68 from being exposed to the lifting arm 92.

In the known procurement or distribution center 100 shown in FIG. 10, items and stocks required to fulfil customer orders are placed in containers or storage boxes 10. One or more storage boxes or storage containers 10 are stacked in a grid column 15a (first grid column). The grid column varies in height depending on the number of storage boxes or storage containers stacked in the grid column. The known procurement center also includes various other stations, including, but not limited to, a charging station for charging rechargeable batteries that power the baggage handling devices on the grid, and a service station for performing routine maintenance of the baggage handling devices. A separate area 102 is provided adjacent the grid framework structure 14 to accommodate any one or combination of the stations. Typically, the separate area 102 is provided by incorporating a mezzanine level 104 supported by vertical beams between adjacent grid framework structures 14, and is typically a freestanding structure. The mezzanine level 104 provides a tunnel, for example, to accommodate a pick-up station and/or any one of the stations described above. FIG. 10 shows grid framework structures 14 on both sides of the tunnel created by the mezzanine 104 suitable for accommodating the inventory handling station assembly of the present invention. Grids 22 from adjacent grid framework structures extend across the top of the mezzanine 104 to connect with the grids 22 on both sides of the mezzanine 104. The inventory handling station assembly is installed below the grid columns 15b, 15b (second grid columns) that extend across the top of the mezzanine 104 so that the grid columns 15b, 15c cooperate with one or more vertical chutes 62 in the feed zone 64 and one or more box lifting devices 68 in the buffer zone 70. As is clear from FIG. 10, the grid columns 15b, 15c at the top of the mezzanine 104 are shallower than the grid columns 15a on both sides of the mezzanine 104, i.e., they can accommodate only one or two layers of containers in a stack. As also shown in FIG. 10, the mezzanine is supported by separate vertical beams. The vertical beams supporting the mezzanine floor abut against the grid framework structure 14 on either side of the mezzanine floor.

One or more package handling devices 30 are operable on the grid or grid structure 14. The package handling devices 30 preferably include a control unit that receives control signals from a wireless communication unit of the control system or a central control system regarding information regarding where to pick and deliver containers or totes within the grid framework structure. For purposes of the present invention, the grid framework structure, the one or more package handling devices operable on the grid framework structure, and the control system for controlling operation of the package handling devices on the grid framework structure form a storage and retrieval system. The storage and retrieval system and the inventory handling station assembly form part of a procurement/replenishment system.

11 is a flow chart 105 showing the steps of the access station 66 of the inventory handling station assembly 60 operating as a pick station. At the pick station, a storage box or container is lifted by the baggage handling device 30 from a stack containing inventory items required to fulfill a customer order. Once lifted by the baggage handling device 30, the storage box or container is delivered by the baggage handling device to a drop port 106, whereby the baggage handling device is commanded by the control system to lower the storage box or container down the chute 62 to the supply zone 108. At the supply zone 64, the storage box is transported by the conveyor system 76, where it is suspended at the access station 66, which doubles as a pick station 110. At the pick station, the required inventory item or items may be manually or robotically removed from the storage box or container and placed in a delivery container 112, which is a delivery container forming part of the customer order, and filled for dispatch at the appropriate time. The pick process is repeated 114 until the items required to fulfill the order are completed. Once the pick stage is completed, the storage container is transported to a buffer zone where the storage containers are vertically stacked 116. Depending on the occupancy of one or more box lifting devices, as discussed above, the storage container or storage container is lifted to its highest position where it waits to be retrieved by a load handling device operable on a grid or grid structure 118. The entire process shown in FIG. 11 is repeated as more storage containers or storage containers are lowered into the inventory handling station assembly to fulfill multiple orders for one or more items.

The access station 66 of the inventory handling station assembly 60 can also double as a decanting or refilling station where palletized items or other batches of items of a particular characteristic SKU arrive at the inventory handling station assembly and are loaded into a storage box or storage container. FIG. 12 is a flow chart 119 showing the steps of refilling a storage box or storage container with inventory or items. A storage box or storage container that needs to be refilled with one or more items can be retrieved from storage in the grid framework structure and delivered to the inventory handling station assembly via one or more chutes in the supply zone 120. Alternatively or in addition, an empty storage box or storage container can be added at the access station and then added to the storage and retrieval system. At the access station, the items of the characteristic SKU are loaded into a storage box or storage container 122. The identification of the characteristic SKU and storage box of the item is stored in an inventory database accessible by the control system or the storage control and communication system (see FIG. 13). The decanting or loading of the container at the access station continues until completion 124. At the access station, weighing or load cells measure the weight of the storage bin or container on at least one access conveyor unit as the items are loaded into the storage bin or container 125. Steps 124 and 125 are performed in unison or simultaneously as the items are transferred to the storage bin or container. As discussed above, the weighing cells are used to determine whether the storage bin or container has reached a predetermined weight above which it would exceed the safe lifting capacity of the lifting mechanism and/or box lifting device 126 of the baggage handling device. Once the required amount of items has been loaded into the storage bin or container and the weight of the storage bin or container is below or equal to the predetermined weight, at least one conveyor unit is enabled to move to a buffer zone where the items are queued before being retrieved by the baggage handling device operable on the grid structure 128, 130. However, if the weight of the storage bin or container is above the predetermined weight, the operator removes one or more items from the storage bin or container until the weight of the storage bin or container reaches the desired weight or is below the predetermined weight 127. The entire process of refilling a storage box or container is repeated with different items or SKUs.

FIG. 13 is a block diagram of components of a procurement system 132 according to an embodiment of the present invention. The procurement system components shown in FIG. 13 are applicable whether the access station is a retrieval station and/or a replenishment station. The operation of the baggage handling devices 30 on the grid is controlled by a control system or controller 134, which comprises one or more processors 136, memory (e.g., read-only memory and random access memory) 140, and a communication bus 138. The control system 134 is communicatively coupled to one or more baggage handling devices 30 operating on the grid via a communication network over a wireless transmitter/receiver (not shown). The communication network may be, for example, a local area network (LAN), a wide area network (WAN), or any other type of network. In a particular embodiment, the baggage handling devices preferably comprise a control unit that receives control signals from a wireless communication unit of the control system. The one or more processors of the control system may execute instructions stored in ROM and/or RAM to control the movement of one or more baggage handling devices operating on the grid. The control system 134 is also communicatively coupled to the inventory handling station assembly 60. The control system 134 receives a signal associated with the weight of the storage bin or container in the access station. The control system 134 may also control the conveyor system 76 and/or the box lifting device 68 to control the movement of the storage bin or container as it is processed through the access station 66 and/or queued in the buffer zone 70. As is commonly known in the art, one or more sensors, e.g., position sensors or proximity sensors, are distributed along the path of the conveyor system 76 and are used to monitor the location of the storage bin or container at different stages along the conveyor system 76, e.g., different zones (feed zone, access station, and buffer zone) in the inventory handling station. A user interface (not shown) communicatively coupled to the control system 134 is provided at the access station to approve the removal or loading of one or more items into or from the storage bin or container. For example, an operator approves that an item of the order is removed from the storage bin and placed into a delivery container by the user interface (not shown). The user interface sends a signal to the control system 134 that the item of the order has been procured. This is repeated until all of the items in the order have been procured. The weight of the storage bin or container can be correlated with the identification of the storage bin or container. The identification can also correspond to the type of item or the SKU of the item stored in the storage bin or container. To identify each of the storage bins or containers, preferably each of the storage bins or containers is provided with a label (e.g., an electronic label) that is readable by a user interface to establish the identity of each of the storage bins or containers. Optionally, the label can comprise a barcode, a 1D barcode, a 2D barcode, or a QR code or an RFID tag. The user interface can be a push button or a graphical user interface (GUI). The identification of the storage bin or container is correlated with the contents of the storage bin or container by its characteristic attribute or SKU.

Data associated with one or more orders is stored in the order database 142. Each of the orders stored in the order database 142 comprises one or more items requested by one or more customers. Each of the items in an order can be characterized by different attributes. As discussed above, the attributes may be SKUs commonly known in the art that are characteristic of the items, such as manufacturer, brand, model, color, and/or size. Data associated with inventory or stock in the storage and retrieval system is stored in the inventory database 144. The data includes attributes of the items characterized by their corresponding SKUs stored in each of the bins or containers, and the location of the bins or containers within the grid framework structure. The location of the bins or containers within the grid framework structure may be represented by three-dimensional Cartesian coordinates to represent the container location and container depth (e.g., bin in (X,Y,Z), depth W). Optionally, the control system 134 can correlate one or more items in an order with corresponding attributes of the items stored in the inventory database 144.

The order database 142 is dynamically updated as more orders are received. Similarly, the inventory database 144 is dynamically updated whenever stock is added to or removed from a bin or storage container. Each time an order for one or more items is placed, the control system 134 accesses the inventory database 144 to determine whether any one of the items is available, the quantity of the item in the inventory database 144, and the location or location of one or more bins or storage containers for sourcing the order within the storage retrieval system, i.e., grid framework structure. Through one or more processors 136, the control system 134 instructs one or more baggage handling devices 30 to locate and retrieve one or more bins or storage containers containing the associated items to fulfil the order.

Typically, delivery containers containing procured orders are transported via conveyor, forklift, or other means to a loading vehicle for shipment to any ordering customer. At the dispatch facility, packaged containers associated with one or more assembled orders may be sorted and delivered to a transportation vehicle, such as a truck, for delivery to the customer. While such a process is appropriate when the timescale for procurement and dispatch of an order generally spans a period of one or more days, such a process is not ideal when an order needs to be procured and dispatched over a period of one or more hours or less, such as immediate dispatch. Immediate dispatch is increasingly prevalent for procurement of convenience grocery items, i.e. staple grocery items, such as milk, cheese, or bread. Here, such orders are either picked and delivered to the customer or dispatched at the storefront from the receipt of the order. Combined with the development of online shopping, this has led to a plethora of different e-commerce models for the purchase of goods for immediate dispatch online. These range from click-and-collect models, where a customer who buys or selects an item online can pick up the item either at a selected in-store or central collection location, or at a home delivery service where the item is delivered directly to the customer's premises. To provide for immediate dispatch of an order, the procurement system can be adapted to include a bagging station where the delivery container comprises one or more bags.

14 shows a bagging station 146 adjacent to the inventory handling station assembly 60 of the present invention where one or more items fulfilling an order are packaged into one or more bags 148. The bagging station 146 can be positioned near the access station 66 such that items removed from one or more storage bins or containers in the access station 66 can be transferred to one or more bags 148 at the bagging station 146. Removal can be done manually by hand or by robot as taught in GB2524383 (Ocado Innovation Limited). The one or more bags 148 at the bagging station 146 are separated or held in different compartments or spaces within the bagging station by one or more partitions 150. The one or more bags 148 are supported on an elevated surface (e.g., table 152) that is divided into separate compartments by the partitions 150. Each of the partitions 150 can represent an individual order or a portion of an order.

The bagging station 146 allows a small number of items, typically convenience items, to be immediately packaged from the access station 66 into one or more bags 148 before being dispatched to the customer. The process of picking up an order by a pick-up station described above with reference to FIG. 11 still applies. The storage and retrieval system can be made on a smaller scale to accommodate requests for a smaller group of items, typically staple or convenience items, such as bread, eggs, milk, etc. An operator at the bagging station 146 acknowledges by a user interface that one or more items have been picked up and transferred to a bag. The bag with the picked up order can be dispatched directly to the customer at the storefront, rather than being processed through a delivery facility. Alternatively, with the growth of click-and-collect offers, the bag with the picked up order can be deposited in an electronically controllable locker for subsequent collection by the customer or a courier. The multiple partitions 150 at the bagging station 146 allow multiple orders to be picked up for immediate dispatch. Each of the compartments provided by the partition 150 includes a user interface 154 for authorizing removal of an ordered item from a storage bin or container.

More particularly, at least one chute is provided with at least one input device, more particularly a reader, for example a primary and/or matrix barcode reader, to identify the identity of the storage bin or container as the baggage handling device lowers the storage bin or container into the supply zone. One or more storage bins are provided with a label readable by the at least one input device to establish the identity and contents of each of the one or more storage bins as they progress under the at least one chute. The label on one or more of the storage bins may be a barcode, 1D barcode, 2D barcode, or QR code or RFID tag. FIG. 14b shows a rear view of the inventory handling station assembly 60 shown in either FIG. 6 or FIG. 14a of the present invention. In the particular embodiment shown in FIG. 14b, three chutes 62 are shown in the supply zone 64. Each of the chutes 62 is provided with a reader or scanner 65 that scans the label of the storage bin or container as it pauses on the entrance conveyor unit. The signal from the reader 65 is used by the control system to identify the storage box or container and its contents within the inventory handling station assembly.

To ensure that the baggage handling device is instructed to retrieve the appropriate storage box or container to the inventory handling station assembly 60, the signal from the reader 65 can also ensure that the storage box or container delivered by the baggage handling device correlates with the identification of the storage box or container in the inventory handling station assembly 60, e.g., provide an electronic handshake between the inventory handling station assembly 60 and the baggage handling device instructed to deliver the storage box or container. Typically, the location or position of each storage box or container within the grid framework structure is stored in an inventory database. When the baggage handling device is instructed to retrieve a storage box or container to fulfill an order, the baggage handling device is instructed to move to a location on the grid where the desired storage box or container is located. The storage box or container is then transported to the inventory handling station assembly. The identification of the storage box or container is read by the reader 65 at the supply zone. This is compared to the identification of the storage bin or storage container instructed by the baggage handling device to see if they correlate to ensure that the appropriate storage bin or storage container is delivered to the inventory handling station assembly 60. To fulfill an order, the control system, via one or more processors, instructs one or more baggage handling devices operable on the grid to retrieve one or more storage bins or storage containers containing the associated items from the storage and retrieval system. In some cases, the baggage handling devices may have to repeatedly retrieve the same storage bin or storage container throughout the day to fulfill multiple orders requesting the same item. This is especially exacerbated when the item is a common convenience or staple item, such as milk, cheese, bread, etc. In another aspect of the invention, the control system 134, in communication with the order database 142 and/or the inventory database 144, is instructed by one or more processors to match or group multiple orders that share a common item type or SKU. When one or more types of items of each of the orders are shared or common among the multiple orders, the multiple orders are grouped or matched to increase the efficiency of procuring the multiple orders, thereby enabling the procurement system to meet the criteria for immediate shipment. An organization unit stored in the memory organizes the orders such that the multiple orders share one or more common items. The process of matching or grouping the multiple orders based on at least one item of the multiple orders being common among the multiple orders can be described by a flowchart 160 shown in FIG. 15. In a first step, the control system accesses data associated with the multiple orders in an order database 162. Through one or more processors, the control system compares the first order of one or more items with the second order of one or more items 164 to determine whether there are one or more items in common between the first order and the second order 166. If one or more items are common between the first order and the second order 166, the control system matches or groups the first order with the second order 168. If there are no common items, the control system revisits the order database to look for other orders that have common items, otherwise the control system proceeds to process the order as described above with reference to FIG. 11.

The control system, through one or more processors, accesses 172 the inventory database 170 to locate the bin or container with the contents of the bin or container storing the associated item and then retrieves it. As discussed above, the inventory database comprises data associated with the list items and their characteristic attributes or SKUs along with the location of the bin or container storing the items. The sequence of steps 168 of matching the first and second orders and 170 of accessing the inventory database is not limited to that shown in FIG. 15 and can be interchanged. At the access station, the contents of the bin or container are shared between the first and second orders. By sharing the bin or container between multiple orders, the ability of the procurement system to procure multiple orders is increased. In general, items common between multiple orders are more prominent if the orders contain convenience or key items.

In a further improvement to increase the efficiency of the procurement system, one or more storage bins or containers 10b, 10c can store two or more different items or SKUs 176a, 176b, as shown in Fig. 16 and Fig. 17. The different items can be separated in the storage bin or container by a distributor 174. Here, the control system matches orders that share common items. For example, an algorithm identifies items that are frequently requested together, i.e., analyzes the frequency distribution of items ordered. These typically include convenience items or major common everyday items with relatively short sell-by dates, e.g., milk, dairy products, etc. One or more storage bins or containers 10b, 10c can be organized in a storage and retrieval system, whereby each of the one or more storage bins or containers can store different items that are frequently ordered together, i.e., have a high frequency distribution of requests. Groups of orders can be matched or grouped together based on groups of items that are common or shared between each of the orders. By grouping or matching multiple orders where different items are common among each of the orders and collecting a single storage bin or container to store the different items, the contents of the single storage bin or container can be shared among multiple delivery containers, e.g., bags, associated with the multiple orders. Thus, in addition to collecting separate storage bins or containers for each item in the multiple orders, the control system can place and collect a storage bin whose contents are shareable among the multiple orders. This not only increases the efficiency of sourcing multiple orders, but also dramatically reduces the number of storage bins or containers that need to be collected to sourcing an order, since the control system is not separately required to collect storage bins or containers for each item in each individual order. The sourcing efficiency is increased and a larger number of different items or SKUs can be stored in a given storage bin, as shown in FIG. 17.

Storing different items in one or more storage boxes or containers such that each of the one or more storage boxes or containers stores multiple different items as shown in FIG. 16 or FIG. 17 similarly increases the likelihood that the contents of any one of the storage boxes or containers being stored can be shared among multiple delivery containers, e.g., bags, associated with multiple orders. For example, a storage box or container may include one or more items having a characteristic first attribute or SKU and one or more items having a characteristic second attribute or SKU, and the storage box or container, or more specifically, the delivery container associated with multiple orders, may include one or more items of the first attribute or second attribute that can be shared among multiple orders.

Table 1 is a hypothetical example of a group of five orders. Each of the labeled orders, i.e., orders 1, 2, 3, 4, and 5, comprises an order of five different items or SKUs with characteristic attributes labeled A, B, C, D, E, and F. Here, orders 1, 2, 3, and 5 share the same required item B. Orders 1, 3, and 5 further share the same required item D, i.e., common items B and D. To increase the efficiency of procuring the five orders, when the control system procures orders 1, 2, 3, and 5, the control system matches or groups orders 1, 2, 3, and 5 such that it can retrieve a single storage bin or container that stores item B, whose contents are shareable between orders 1, 2, 3, and 5. This is further increased if a single storage bin or container stores items of both types B and D, such that the contents of the single storage bin or container are shareable between orders 1, 3, and 5. This greatly speeds up the fulfillment of the five orders, as fewer storage boxes or containers need to be repeatedly retrieved from the storage and retrieval system (grid framework structure) to fulfill multiple orders.

The invention as originally claimed in the present application is set forth below.
[1] An inventory handling station assembly 60 for a storage and retrieval system, said storage and retrieval system comprising:
a plurality of upright columns 16 arranged to form a plurality of grid columns 15 in one or more vertical planes, for one or more containers 10 to be stacked between and vertically guided by the plurality of upright columns 16, the plurality of upright columns 16 being interconnected at their upper ends by a first set of grid members 18 extending in a first direction and a second set of grid members 20 extending in a second direction, the second set of grid members 20 moving transversely in a substantially horizontal plane to the first set of grid members 18 to form a grid comprising a plurality of grid cells or grid spaces;
a grid framework structure 14 comprising:
the first set of grid members 18 and the second set of grid members 20 respectively support a first set of tracks 22a and a second set of tracks 22b for a load handling device 30 to move one or more containers 10 on the grid framework structure 14 at an upper level of the grid framework structure 14;
wherein the inventory handling station assembly 60 is
i) a feed zone 64 comprising at least one vertical chute 62 configurable to cooperate with at least one upright column 16, said at least one vertical chute 62 having a first opening for receiving a container 10 lowered by at least one baggage handling device 30 through a grid cell, and a second opening for allowing said container 10 to exit said feed zone 64;
ii) a buffer zone 70 for vertically stacking one or more containers 10 with at least one box lifting device 68, said at least one box lifting device 68 being positionable to lift a container 10 upwards towards said grid such that, in use, said container 10 can be retrieved by said at least one baggage handling device 30;
iii) an access station 66 intermediate the feed zone 64 and the buffer zone 70 to provide access to one or more containers 10 exiting the feed zone 64;
iv) a conveyor system 76 configured to transport one or more containers 10 from the supply zone 64 to the buffer zone 70 via the access station 66;
An inventory handling station assembly 60 comprising:
[2] the conveyor system 76 comprises an entrance conveyor unit 78, an exit conveyor unit 82, and at least one access conveyor unit 80, wherein:
the inlet conveyor unit 78 is disposed within the feed zone 64 and is arranged to convey containers 10 in a first conveying direction from the second opening of the at least one vertical chute 62 to the at least one access conveyor unit 80;
the exit conveyor unit 82 is disposed within the buffer zone 70 and is arranged to convey containers 10 from the at least one access conveyor unit 80 to the buffer zone 70 in a second conveying direction;
The inventory handling station assembly 60 of [1], wherein the at least one access conveyor unit 80 is arranged to transport containers 10 from the supply zone 64 to the buffer zone 70 via the access station 66 in a third transport direction.
[3] The inventory handling station assembly 60 of [2], wherein the entrance conveyor unit 78 and the exit conveyor unit 82 are arranged such that the first conveying direction of the entrance conveyor unit 78 is opposite and parallel to the second conveying direction of the exit conveyor unit 82, and wherein the third conveying direction of the at least one access conveyor unit 80 is perpendicular to both the first conveying direction of the entrance conveyor unit 78 and the second conveying direction of the exit conveyor unit 82.
[4] The inventory handling station assembly 60 of [2], wherein the conveyor system 76 is positioned such that the first conveying direction of the entrance conveyor unit 78 is perpendicular to both the second conveying direction of the exit conveyor unit 82 and the third conveying direction of the at least one access conveyor unit 80.
[5] The inventory handling station assembly 60 of any one of [2] to [4], wherein the at least one access conveyor unit 80 is equipped with a load cell for weighing containers.
[6] The inventory handling station assembly 60 of [4], wherein the at least one access conveyor unit 80 comprises a plurality of adjacent conveyor units arranged to transport containers 10 horizontally from the supply zone 64 to the buffer zone 70 via the access station 66.
[7] The inventory handling station assembly 60 of [6], wherein each of the plurality of conveyor units is arranged to accommodate a single container 10.
[8] The inventory handling station assembly 60 of [6] or [7], wherein at least one of the plurality of conveyor units is equipped with the load cell.
[9] The inventory handling station assembly 60 of [8], comprising a work surface 86 disposed above the at least one access conveyor unit 80, the work surface 86 having an opening providing access to a container 10 on the at least one of the plurality of conveyor units.
[10] An inventory handling station assembly 60 as described in any one of [1] to [9], wherein the at least one box lifting device 68 comprises two parallel arms 92 engageable with a bottom wall of a container 10 and a lifting mechanism arranged to move the two parallel arms 92 vertically from a lowest level below the conveyor system 76 to a highest level above the conveyor system 76.
[11] The inventory handling station assembly 60 of [10], wherein the two parallel arms 92 are spaced apart a distance greater than a width of the exit conveyor unit 82.
[12] An inventory handling station assembly 60 as described in any one of [1] to [11], wherein the at least one vertical chute 62 includes at least two vertical guides 72 for guiding a container 10 vertically along the at least one vertical chute 62, each of the at least two vertical guides 72 being receivable within a grid column 15.
[13] The inventory handling station assembly 60 of [12], wherein each of the at least two vertical guides 72 of the at least one vertical chute 62 comprises two orthogonal plates extending along the length of the at least one vertical chute 62.
[14] The inventory handling station assembly 60 of [12] or [13], further comprising a sidewall 74 surrounding the at least one vertical chute 62.
[15] A) A storage and retrieval system comprising a grid framework structure 14, said grid framework structure 14 comprising:
a) a plurality of upright columns 16 in one or more vertical planes and arranged to form a plurality of grid columns 15 for one or more containers 10 to be stacked between and vertically guided by said plurality of upright columns 16;
the plurality of upright columns 16 are interconnected at their upper ends by a first set of grid members 18 extending in a first direction and a second set of grid members 20 extending in a second direction, the second set of grid members 20 moving transversely to the first set of grid members 18 in a substantially horizontal plane to form a grid comprising a plurality of grid cells or grid spaces;
the first set of grid members 18 and the second set of grid members 20 respectively support a first set of tracks 22a and a second set of tracks 22b for a load handling device 30 to move one or more containers 10 on the grid framework structure 14 at an upper level of the grid framework structure 14;
b) one or more containers 10, each of said one or more containers 10 comprising one or more items characterized by attributes;
c) one or more luggage handling devices 30 remotely operated to move the one or more containers 10 stored within the grid framework structure 14, each of the one or more luggage handling devices 30 comprising:
i) a wheel assembly for guiding the luggage handling device 30 on the grid;
ii) a container receiving space 40 located above said grid;
iii) a lifting device arranged to lift a single container 10 from the stack 12 into said container receiving space 40;
Equipped with
Equipped with
B) A procurement/replenishment system comprising an inventory handling station assembly 60 as described in any one of [1] to [14] and the one or more luggage handling devices 30, which are remotely operated to move the one or more containers 10 stored in the grid framework structure 14 to and/or from the inventory handling station assembly 60.
16. The procurement/replenishment system of claim 15, wherein the plurality of grid columns comprises a first set of grid columns and a second set of grid columns, wherein the first set of grid columns is arranged to store one or more containers in a stack, and wherein the inventory handling station assembly is arranged below the second set of grid columns such that, in use, a baggage handling device operable on an upper level of the grid framework structure can lower a container through the at least one grid column and down the at least one vertical chute, and the at least one box lifting device is arranged below the at least one grid column such that the at least one vertical chute and the at least one box lifting device are operable to lift a container through the at least one grid column and into the container receiving space of the baggage handling device.
[17] The procurement/replenishment system of [16], wherein the second set of grid columns is supported by a mezzanine level 104.
[18] The procurement/replenishment system of [16] or [17], wherein the second set of grid columns comprises at least one delivery column 15b and at least one return column 15c, the at least one chute 62 being positioned below the at least one delivery column 15b and the at least one box lifting device 68 being positioned below the at least one return column 15c.
[19] The procurement/replenishment system of any of [16] to [18], further comprising a bagging station 146, the bagging station 146 comprising a table having a surface for supporting one or more bags 148 and at least one user interface 154 in communication with a bagging station control system.
[20] The procurement/replenishment system of [19], wherein the table is divided into one or more spaces by one or more partitions 150, and each of the one or more spaces is provided with at least one user interface 154.
[21] The procurement/replenishment system of [19] or [20], further comprising a plurality of electronically controllable lockers, each of the plurality of electronically controllable lockers comprising a compartment sized to accommodate the one or more bags 148.
[22] The storage and retrieval system, when executed by one or more processors 136 in response to receiving a plurality of orders, includes causing the one or more processors 136 to:
i) grouping or matching the plurality of orders based on a commonality among the plurality of orders of at least one attribute of the one or more items;
ii) generating a signal instructing the luggage handling device 30 to retrieve a first container storing the one or more items common to the plurality of orders;
iii) generating a signal instructing the luggage handling device 30 to lower the first container through the at least one grid column 15 and down the at least one vertical chute 62;
iv) instructing a conveyor system 76 to convey the first container to the access station 66 such that the one or more items common to the plurality of orders can be transferred to a plurality of delivery containers associated with the plurality of orders;
v) instructing the conveyor system 76 to convey the first container to the buffer zone 70.
The procurement/replenishment system of any one of claims [16] to [21] further comprises a control system 134 having a memory 140 for storing instructions.
[23] The control system 134 may be configured to cause the one or more processors 136 to:
v) generating a signal instructing the luggage handling device 30 to retrieve a second container storing the one or more items common to the plurality of orders;
vi) generating a signal instructing the luggage handling device 30 to lower the second container through the at least one grid column 15 and down the at least one vertical chute 62;
vii) instructing the conveyor system 76 to convey the second container to the access station 66 such that the one or more items common to the plurality of orders can be transferred to a plurality of delivery containers associated with the plurality of orders;
viii) commanding the conveyor system 76 to convey the second container to the buffer zone 70;
The procurement/replenishment system of [22], further configured to execute instructions.
[24] The procurement/replenishment system of [23], wherein the control system 134 is further configured to cause the one or more processors 136 to execute instructions to generate signals instructing the one or more baggage handling devices 30 to retrieve the first container and/or the second container from the buffer zone 70 via the at least one grid column 15.
[25] The procurement/replenishment system of any one of [22] to [24], wherein the first container comprises one or more items of a first attribute and one or more items of a second attribute, and wherein the one or more items of the first attribute and/or the one or more items of the second attribute are common among the multiple orders.
[26] The storage and retrieval system further comprises an order database 142 comprising data associated with a plurality of orders for one or more items;
wherein the control system 134 is configured to access the order database 142 to group or match the multiple orders based on at least one attribute of the one or more items being common among the multiple orders.
[27] The procurement/replenishment system of [26], wherein the storage and retrieval system further comprises an inventory database 144 comprising data on at least one attribute of one or more items.
[28] The procurement/replenishment system of any one of [22] to [27], wherein the control system 134 is further instructed to record weights of one or more containers in the access station 66.
[29] The procurement/replenishment system of any one of [19] to [28], wherein the at least one box lifting device 68 comprises a first box lifting device and a second box lifting device, and the control system 134 is configured to instruct the conveyor system 76 to transport a container 10 to the first box lifting device or the second box lifting device depending on occupancy of the first box lifting device and the second box lifting device.
[30] The procurement/replenishment system of [29], wherein the occupancy of the first box lifting device and the second box lifting device is determined by one or more sensors within the first box lifting device and the second box lifting device.
[31] A method of fulfilling a plurality of orders by the procurement/replenishment system of any one of [22] to [30], each of the plurality of orders comprising one or more items, the method comprising:
i) grouping or matching the plurality of orders, each of which comprises one or more items, based on the plurality of orders having at least one attribute common to each of the plurality of orders;
ii) identifying a first container comprising the one or more items having at least one attribute common to each of the plurality of orders;
iii) instructing one or more baggage handling devices 30 to retrieve the first container storing the one or more items from the grid framework structure 14;
iv) lowering the first container via one or more vertical chutes 62 into a feeding zone 64;
v) conveying the first container to an access station 66;
vi) transferring the one or more items from the first container to a plurality of delivery containers associated with the plurality of orders;
vii) conveying said first container to a buffer zone 70;
viii) lifting the first container towards a grid;
ix) instructing the one or more baggage handling devices 30 operable on the grid to retrieve the first container from the buffer zone 70 and return the first container to the grid framework structure 14;
A method comprising:
[32] i) identifying a second container comprising the one or more items having at least one of the attributes common to each of the plurality of orders;
ii) instructing the one or more baggage handling devices 30 to retrieve the second container storing the one or more items from the grid framework structure 14;
iii) lowering the second container via the at least one vertical chute 62 into the feeding zone 64;
iv) conveying the second container to the access station 66;
v) transferring the one or more items from the second container to the plurality of delivery containers associated with the plurality of orders;
vi) conveying said second container to said buffer zone 70;
vii) lifting the second container towards the grid;
viii) instructing the one or more baggage handling devices 30 operable on the grid to retrieve the second container from the buffer zone 70 and return the second container to the grid framework structure 14;
The method according to [31], further comprising:
[33] The method of [31] or [32], wherein the first delivery container and/or the second delivery container is a bag.
[34] The method of any one of [31] to [33], further comprising the step of transporting the one or more bags to one or more electronically controllable lockers.
[35] The method of any one of [31] to [34], further comprising the step of weighing one or more containers in the access station 66.

Claims (31)

1. An inventory handling station assembly 60 for a storage and retrieval system, said storage and retrieval system comprising a grid framework structure 14 ,
a plurality of upright columns 16 arranged to form a plurality of grid columns 15 in one or more vertical planes, for one or more containers 10 to be stacked between and vertically guided by said plurality of upright columns 16, said plurality of upright columns 16 being interconnected at their upper ends by a first set of grid members 18 extending in a first direction and a second set of grid members 20 extending in a second direction, said second set of grid members 20 extending transversely in a substantially horizontal plane to said first set of grid members 18 to form a grid comprising a plurality of grid cells or grid spaces;
the first set of grid members 18 and the second set of grid members 20 respectively support a first set of tracks 22a and a second set of tracks 22b for a load handling device 30 to move one or more containers 10 on the grid framework structure 14 at an upper level of the grid framework structure 14;
wherein the inventory handling station assembly 60 is
i) a feed zone 64 comprising at least one vertical chute 62 configurable to cooperate with at least one upright column 16, said at least one vertical chute 62 having a first opening for receiving a container 10 lowered by at least one baggage handling device 30 through a grid cell, and a second opening for allowing said container 10 to exit said feed zone 64;
ii) a buffer zone 70 for vertically stacking one or more containers 10 with at least one box lifting device 68, said at least one box lifting device 68 being positionable to lift a container 10 upwards towards said grid such that, in use, said container 10 can be retrieved by said at least one baggage handling device 30;
iii) an access station 66 intermediate the feed zone 64 and the buffer zone 70 to provide access to one or more containers 10 exiting the feed zone 64;
iv) a conveyor system 76 configured to transport one or more containers 10 from the supply zone 64 to the buffer zone 70 via the access station 66 ;
The conveyor system 76 includes an entrance conveyor unit 78, an exit conveyor unit 82, and at least one access conveyor unit 80, wherein:
the inlet conveyor unit 78 is disposed within the feed zone 64 and is arranged to convey containers 10 in a first conveying direction from the second opening of the at least one vertical chute 62 to the at least one access conveyor unit 80;
the exit conveyor unit 82 is disposed within the buffer zone 70 and is arranged to convey containers 10 from the at least one access conveyor unit 80 to the buffer zone 70 in a second conveying direction;
the at least one access conveyor unit 80 is arranged to convey containers 10 from the supply zone 64 to the buffer zone 70 via the access station 66 in a third conveying direction;
the conveyor system 76 is arranged such that the first conveying direction of the entrance conveyor unit 78 is perpendicular to the third conveying direction of the at least one access conveyor unit 80;
the first conveying direction of the entrance conveyor unit 78 is perpendicular to the second conveying direction of the exit conveyor unit 82 or opposite and parallel to the second conveying direction of the exit conveyor unit 82;
The at least one access conveyor unit 80 comprises a plurality of adjacent conveyor units arranged to transport containers 10 horizontally from the feed zone 64 to the buffer zone 70 through the access station 66.
, inventory handling station assembly 60 . The inventory handling station assembly of claim 1 , wherein said at least one access conveyor unit includes a load cell for weighing containers. The inventory handling station assembly (60) of claim 1 , wherein each of the plurality of conveyor units is arranged to accommodate a single container (10). The inventory handling station assembly of claim 2 , wherein at least one of a plurality of conveyor units includes said load cell. 5. The inventory handling station assembly 60 of claim 4, further comprising a work surface 86 disposed above the at least one access conveyor unit 80, the work surface 86 having an opening allowing access to a container 10 on the at least one of the plurality of conveyor units. An inventory handling station assembly 60 as described in any one of claims 1 to 5, wherein the at least one box lifting device 68 comprises two parallel arms 92 engageable with a bottom wall of a container 10 and a lifting mechanism arranged to move the two parallel arms 92 vertically from a lowest level below the conveyor system 76 to a highest level above the conveyor system 76. 7. The inventory handling station assembly (60) of claim 6 , wherein said two parallel arms (92) are spaced apart a distance greater than a width of said exit conveyor unit (82). An inventory handling station assembly 60 as described in any one of claims 1 to 7, wherein the at least one vertical chute 62 has at least two vertical guides 72 for guiding a container 10 vertically along the at least one vertical chute 62, each of the at least two vertical guides 72 being receivable within a grid column 15. 9. The inventory handling station assembly 60 of claim 8 , wherein each of the at least two vertical guides 72 of the at least one vertical chute 62 comprises two orthogonal plates extending along the length of the at least one vertical chute 62. 10. The inventory handling station assembly (60) of claim 8 or 9 , further comprising a sidewall (74) surrounding said at least one vertical chute (62). A) a storage and retrieval system comprising a grid framework structure 14;
The grid framework structure 14 is
a) a plurality of upright columns 16 in one or more vertical planes and arranged to form a plurality of grid columns 15 for one or more containers 10 to be stacked between and vertically guided by said plurality of upright columns 16, said plurality of upright columns 16 being interconnected at their upper ends by a first set of grid members 18 extending in a first direction and a second set of grid members 20 extending in a second direction, said second set of grid members 20 extending transversely to said first set of grid members 18 in a substantially horizontal plane to form a grid comprising a plurality of grid cells or grid spaces, said first set of grid members 18 and said second set of grid members 20 respectively supporting a first set of tracks 22a and a second set of tracks 22b for a luggage handling device 30 to move one or more containers 10 on said grid framework structure 14 at an upper level of said grid framework structure 14,
b) one or more containers 10, each of said one or more containers 10 comprising one or more items characterized by attributes;
c) one or more luggage handling devices 30 remotely operated to move the one or more containers 10 stored within the grid framework structure 14, each of the one or more luggage handling devices 30 comprising:
i) a wheel assembly for guiding the luggage handling device 30 on the grid;
ii) a container receiving space 40 located above said grid;
iii) a lifting device arranged to lift a single container 10 from the stack 12 into said container-receiving space 40 ;
Equipped with
B) an inventory handling station assembly 60 according to any one of claims 1 to 10 ;
the one or more load handling devices 30 are remotely operated to move the one or more containers 10 stored on the grid framework structure 14 to and/or from the inventory handling station assembly 60 ;
A procurement/replenishment system comprising: 12. The procurement/replenishment system of claim 11, wherein the plurality of grid columns 15 comprises a first set of grid columns and a second set of grid columns, wherein the first set of grid columns is arranged to store one or more containers 10 in a stack 12, and wherein the inventory handling station assembly 60 is arranged below the second set of grid columns such that, in use, a baggage handling device 30 operable on an upper level of the grid framework structure 14 can lower a container 10 through the at least one grid column 15 and down the at least one vertical chute 62, and the at least one box lifting device 68 is arranged below the at least one grid column 15 such that the at least one vertical chute 62 and the at least one box lifting device 68 are operable to lift a container 10 to be removed through the at least one grid column 15 and into the container receiving space 40 of the baggage handling device 30. The procurement/replenishment system of claim 12 , wherein the second set of grid columns is supported by a mezzanine level 104 . 14. The procurement/replenishment system of claim 12 or 13, wherein the second set of grid columns comprises at least one delivery column 15b and at least one return column 15c , at least one chute 62 is positioned below the at least one delivery column 15b and the at least one box lifting device 68 is positioned below the at least one return column 15c . 15. The procurement/replenishment system of claim 12, further comprising a bagging station (146), the bagging station (146) comprising a table having a surface for supporting one or more bags (148) and at least one user interface ( 154 ) in communication with a bagging station control system. The procurement/replenishment system of claim 15 , wherein the table is divided into one or more spaces by one or more partitions 150 , each of the one or more spaces comprising the at least one user interface 154 . 17. The procurement/replenishment system of claim 15 or 16, further comprising a plurality of electronically controllable lockers, each of said plurality of electronically controllable lockers comprising a compartment sized to accommodate said one or more bags 148 . The storage and retrieval system, when executed by one or more processors 136 in response to receiving a plurality of orders, may include causing the one or more processors 136 to:
i) grouping or matching the plurality of orders based on at least one attribute of the one or more items being common among the plurality of orders;
ii) generating a signal instructing the luggage handling device 30 to retrieve a first container storing the one or more items common to the plurality of orders;
iii) generating a signal instructing the luggage handling device 30 to lower the first container through the at least one grid column 15 and down the at least one vertical chute 62;
iv) instructing a conveyor system 76 to convey the first container to the access station 66 such that the one or more items common to the plurality of orders can be transferred to a plurality of delivery containers associated with the plurality of orders;
v) instructing the conveyor system 76 to transport the first container to the buffer zone 70 . The control system 134 may be configured to cause the one or more processors 136 to:
v) generating a signal instructing the luggage handling device 30 to retrieve a second container storing the one or more items common to the plurality of orders;
vi) generating a signal instructing the luggage handling device 30 to lower the second container through the at least one grid column 15 and down the at least one vertical chute 62;
vii) instructing the conveyor system 76 to convey the second container to the access station 66 such that the one or more items common to the plurality of orders can be transferred to a plurality of delivery containers associated with the plurality of orders;
20. The procurement/replenishment system of claim 18 , further configured to execute instructions: viii) instructing the conveyor system 76 to transport the second container to the buffer zone 70. 20. The procurement/replenishment system of claim 19, wherein the control system 134 is further configured to cause the one or more processors 136 to execute instructions to generate a signal instructing the one or more baggage handling devices 30 to retrieve the first container and/or the second container from the buffer zone 70 via the at least one grid column 15 . 21. The procurement/replenishment system of claim 18, wherein the first container comprises one or more items of a first attribute and one or more items of a second attribute, and wherein the one or more items of the first attribute and/or the one or more items of the second attribute are common among the multiple orders. the storage and retrieval system further comprising an order database 142 comprising data associated with a plurality of orders for one or more items;
22. The procurement/replenishment system of any one of claims 18 to 21, wherein the control system 134 is configured to access the order database 142 to group or match the multiple orders based on at least one attribute of the one or more items being common among the multiple orders. 23. The procurement/replenishment system of claim 22 , wherein the storage and retrieval system further comprises an inventory database 144 comprising data for at least one attribute of one or more items. 24. The procurement/replenishment system of any one of claims 18 to 23 , wherein the control system (134) is further instructed to record a weight of one or more containers in the access station (66). 25. The procurement/replenishment system of any one of claims 18 to 24, wherein the at least one box lifting device 68 comprises a first box lifting device and a second box lifting device, and the control system 134 is configured to instruct the conveyor system 76 to transport a container 10 to the first box lifting device or the second box lifting device depending on occupancy of the first box lifting device and the second box lifting device. 26. The procurement/replenishment system of claim 25, wherein the occupancy of the first box lifting device and the second box lifting device is determined by one or more sensors within the first box lifting device and the second box lifting device. 27. A method of fulfilling a plurality of orders by a procurement/replenishment system according to any one of claims 18 to 26 , each of the plurality of orders comprising one or more items, the method comprising:
i) grouping or matching the plurality of orders, each of which comprises one or more items, based on the plurality of orders having at least one attribute common to each of the plurality of orders;
ii) identifying a first container comprising the one or more items having at least one attribute common to each of the plurality of orders;
iii) instructing one or more baggage handling devices 30 to retrieve the first container storing the one or more items from the grid framework structure 14;
iv) lowering the first container via one or more vertical chutes 62 into a feeding zone 64;
v) conveying the first container to an access station 66;
vi) transferring the one or more items from the first container to a plurality of delivery containers associated with the plurality of orders;
vii) conveying said first container to a buffer zone 70;
viii) lifting the first container towards a grid;
ix) instructing the one or more baggage handling devices 30 operable on the grid to retrieve the first container from the buffer zone 70 and return the first container to the grid framework structure 14. i) identifying a second container comprising the one or more items having at least one of the attributes common to each of the plurality of orders;
ii) instructing the one or more baggage handling devices 30 to retrieve the second container storing the one or more items from the grid framework structure 14;
iii ) lowering the second container via at least one vertical chute 62 into the feeding zone 64;
iv) conveying the second container to the access station 66;
v) transferring the one or more items from the second container to the plurality of delivery containers associated with the plurality of orders;
vi) conveying said second container to said buffer zone 70;
vii) lifting the second container towards the grid;
and viii) instructing the one or more baggage handling devices 30 operable on the grid to retrieve the second container from the buffer zone 70 and return the second container to the grid framework structure 14 . 29. The method of claim 27 or 28 , wherein the delivery container is a bag. 30. The method of any one of claims 27 to 29 , further comprising the step of transporting the one or more bags to one or more electronically controllable lockers. 31. The method of any one of claims 27 to 30 , further comprising the step of weighing one or more containers in the access station 66.

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